Assembly - November 2008 - (Page 57) very hectic pace. If they are the line rate, the operator not trained in techniques and would use the fake joint basic fastening strategy, they to trick the error-proofing can easily miss an obvious routine programmed into the joint failure. With air tools, tool and thus avoid stopping the only way to determine if a the line. fastener is correctly tightened Such stories underscore is by feel. Seasoned operators the importance of adequate know if the tool shut off training. “A well-trained correctly or if it stalled. operator who takes pride in Operators who are poorly contributing to the assembly trained might think they are process is still the best tightening everything right, insurance against errors,” but they may let hundreds of Staiger points out. incorrect joints out the door Training operators to before someone notices. use power tools is more “This issue is less of a complicated than simply concern with DC electric or s h ow i n g t h e m h ow t o cordless tools, because the pull the trigger, says Alan tools provide feedback in Hirschmugl, marketing the form of lights and tones. and training manager with This certainly does not mean AIMCO (Portland, OR). that all screws tightened by Supervisors must understand [these tools] will be perfect. the line conditions and vary Operators must know what their training depending on those lights and tones are This DC electric nutrunner shuts off automatically when a preset torque the production rate, access telling them. As strange is reached. Visual and audible signals tell the operator if the joint is to the assembly, the type of good or bad. Photo courtesy Atlas Copco Tools & Assembly Systems as it sounds, I have seen tool, and the workers’ level applications where smart cordless ignore or even subvert error-proofing of experience. tools are used incorrectly because the technology. Staiger recalls visiting “For example, I once instructed a operators have no idea what the red an assembly line where an operator manufacturing engineer how to use an or green lights mean.” kept a “simulated joint” on a work angle nutrunner, but all the training What’s more, operators can cart. Attempting to work ahead of was done in the tool crib,” recalls Hirschmugl. “Soon after, the engineer called to say the tool was not accurately delivering torque. When I checked on the problem, I found that the way I had shown him to use the tool wouldn’t work with his particular assembly. Because of limited access to the part, the operator would anticipate the torque reaction and prematurely stop running the tool. By working with the operator to find a better working position, the problem was solved.” A ASSEMBLY ONLINE For more information on power tools, visit www.assemblymag.com to read these articles: Tools Work Smarter, Not Harder. The controller for a DC electric tool monitors the electrical performance of the motor and tracks how many hours the tool has run. If problems occur, the controller will shut down the tool. Photo courtesy Atlas Copco Tools & Assembly Systems Current Trends in Electric Tools. Don’t Shut off the Air. www.assemblymag.com November 2008 / ASSE M B LY 57 http://www.assemblymag.com http://www.assemblymag.com
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