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pdboilermaker
OK guys and gals, here is the problem. I work in the automotive industry and our biggest RPN issues are missing/cross threaded bolts, we have tried several things to combat this issue all have met wih moderate success at best.
1. Training (have always done) - All people putting in bolts have been trained, retrained, retrained, and retrained.
2. Audits (have always done)- Audits are performed to make sure that the associates are following the correct sequence of their operation manuals.
4. Click wrench (have always done) - After bolt is tightened, ratchet clicker wrench is used to force operator to check for bolt presence and torque, hopefully a cross threaded condition is caught.
5. Sequential verification (have always done) - An associate other that the one that put in the bolts and used the ratchet clicker puts a verification mark on the bolts to confirm presence of bolt and hopefully detect a cross hreaded condition)
6. Atlas copco electric guns (used on several trial applications but discontinued) - Worked well to catch both cross threaded (bolt angle) and missing (limit switch interlock) bolts, problems were too slow, durability, poor ergonomics for our application, expensive.
7. Yakota pulse air guns (currently used for all bolt applications) - Work well to catch missing bolts (limit switch interlock) problems include cannot be programmed to catch a cross thread condition in our application because the torque angle does not require enough countable pulses.
Yet with all of these human and mechanical controls in place, we still miss an occasional bolt but mostly cross thread them.
IDEAS APPRECIATED
1. Training (have always done) - All people putting in bolts have been trained, retrained, retrained, and retrained.
2. Audits (have always done)- Audits are performed to make sure that the associates are following the correct sequence of their operation manuals.
4. Click wrench (have always done) - After bolt is tightened, ratchet clicker wrench is used to force operator to check for bolt presence and torque, hopefully a cross threaded condition is caught.
5. Sequential verification (have always done) - An associate other that the one that put in the bolts and used the ratchet clicker puts a verification mark on the bolts to confirm presence of bolt and hopefully detect a cross hreaded condition)
6. Atlas copco electric guns (used on several trial applications but discontinued) - Worked well to catch both cross threaded (bolt angle) and missing (limit switch interlock) bolts, problems were too slow, durability, poor ergonomics for our application, expensive.
7. Yakota pulse air guns (currently used for all bolt applications) - Work well to catch missing bolts (limit switch interlock) problems include cannot be programmed to catch a cross thread condition in our application because the torque angle does not require enough countable pulses.
Yet with all of these human and mechanical controls in place, we still miss an occasional bolt but mostly cross thread them.
IDEAS APPRECIATED