Tool maintenance and production optimization - Atlas Copco

Repair Service in a boxFast, high quality repairs1. Place the broken tool in the box. 2. Sign up for direct repair according to the fixed price or a quote. 3. The tool is repaired, tested and sent back to you with a full report.With today’s high demands on minimizing downtime forour customers, we focus on specialized workshops that canhandle quick repairs and complete overhauls in the mostcost-efficient way. To do that we keep a large inventory ofspare parts in stock, and we have upgraded with factoryfixtures and test equipment to increase our efficiency. Withall this, plus certified mechanics dedicated to specific toolmodels, we’ve minimized lead times and improved thequality of each repair. After service all tools are rigorouslytested to Atlas Copco specifications.Customer valuesKey Performance IndicatorFEATUREFixed Price System withservice boxes.Change of service kit.Centralized factory repairs.Service report withcomments.Tested according toAtlas Copco specifications.BENEFITSimple and quick repairs.Reduced Life Cycle Cost.Short turnaround times andconsistent quality.Documented problems withair lines, incorrect tool use,etc.High quality repairs.Days, turnaround time1614121086420Quote timeShipmentSpare partsRepair timeGlobal target2008 2009 2010 2011Our global target is 5 days turnaround time. To maintaina high level of quality, we also track the warrantyon repairs. The above graph shows a leadtime KPIfrom our Central Service Workshop in Europe.8

CalibrationAn efficient way to control qualityWith our network of calibration laboratories we can offera complete package of calibration services to help youcontrol quality for all assembly tools and measurementequipment in your production. Traceability and document management Calibration/verification of transducerized toolsand controllers Torque adjustment and capability test Verification test for a specific application Accredited and factory calibration ofmeasurement equipment Testing and calibration of click and torque wrenches Other special requests, such as angle calibration, etc. We remind you for your next calibrationCustomer valuesCalibration ProcessFEATUREQuality assurance inproduction.Complete calibrationservice from one supplier.Calibration management.Global network ofacc redited calibration labs.BENEFITCompliance withquality requirements.Cost savings in investments,administration, logistics,training, etc.Documented assurance ofcorrect equipmentcalibration.Your calibration meets alllocal standards andrequirements.Inspection OfThe CalibrationObjectIs The ObjectCalibratable?CalibrationAccording To GivenProcedureCheck IfThe Results AreIn OrderOK/NOK?NoDocument AsNon-conformity– Process ErrorOr Tool Or ObjectNeeds ServiceNoYesDocument AsNon-conformityService NeededCheck Of TheResults AgainstTolerancesAdjustment OfCalibration ObjectYesAdjustmentNeeded?NoDocumentaionIncluding IssuingOf Certification10

Preventive MaintenanceHighest uptime and lowest cost in your productionArea of savingsEst. SavingsLower tool effiency cost € 30 400Tool failure cost € 12 000Extra back-up tool cost € 6 000Tool replacement cost € 6 000Quality cost € 3 000POTENTIAL TOTAL COST SAVINGS € 57 400Operating Cost Savings CalculatorLike other machines, Atlas Copco industrial power tools needregular maintenance in order to fulfill their full potential interms of performance and reliability. Different agreements areavailable, tailored to your needs.We offer maintenance both on-site or off-site, or a combination.With our Operating Cost Calculator, you can calculatethe potential savings a preventive maintenance program willprovide for your specific operation.Customer valuesKey Performance IndicatorFEATURERegular preventivemaintenance programs.Fixed annual cost.Maintenance programbased on your tool usage.BENEFITLess downtime andemergency repairs.Consistently highproduction quality.Extended tool life.Control over yourmaintenance budget.With our experience fromseveral PM agreementswe can detect the optimumprogram for you.No. of failures trendRepair PM PM PM PM PM PM300 000 20.0250 000200 000150 000100 00050 00000.0300 000 1.80Yearly production volume (cars)250 000Number of failures per 100 000 cars200 000Yearly production volume(cars)150 000100 00050 0000Y2005Y2006Y2007Y2008Y2009Y2010Y20111.601.401.201.000.800.600.400.200.0015.010.05.0Operating costs($/car)11

Preventive MaintenanceHighest uptime and lowest cost in your productionBy keeping your assembly tool in the low risk area the chance of failures and torque scatter is minimized.100%PERFORMANCEQuality jointsRisk for lowquality jointsOptimized Preventive MaintenanceStandard Preventive MaintenanceRepair on breakdownRUNNING TIMECorrect lubrication of all gears is crucial for highly productive industrial tools. The most common cause of oil/grease leakage isworn seals.100%Optimal performancePERFORMANCEPreventiveMaintenanceneededTool breakdownRUNNING TIME12

Preventive MaintenanceHighest uptime and lowest cost in your productionOil level decrease in small steps during operation and could end up in a destroyed pulse unit.Most of our customer have to replace the tool because of that.Recommended oil levelSPEED, TORQUEOptimalperformanceRisk of destroyed pulse unit100%OIL LEVELCustomer savings: GrindersA group of LSV38 grinders that had been in operation forabout 200 hours at a Nordic customer was tested.Tests were performed in our R&D laboratory both beforeand after preventive maintenance (PM).Result: After PM, power had increased by 16% and airefficiency had improved by 18%. This reduced energycosts and CO 2emissions by 18%.Youtube video: search for ”Energy savings throughPreventive Maintenance” or ”Atlas Copco LSV 38”Customer savings: Assembly toolsA group of 50 functioning Pulse Tools sent in for maintenancewas selected from our central repair shop. Thetools were tested before and after preventive maintenance(PM) on the same hard joint. The tightening time toshut-off was measured.Result: After PM the average tightening time decreased bymore than half (100%) resulting in a corresponding decreasein air consumption and CO 2emissions.Youtube video: search for ”Ergo Pulse Atlas Copco”13

Full CoveragePuts you in full controlOur Full Coverage option keeps your power tools in top operatingcondition and gives you a fixed budget for all tool maintenance.Other services can be added. To develop the optimumservice program for your specific manufacturing operation,take advantage of our unique ToolScan RCM process. For yournew tools, take a look at our ToolCover product on page 26.Full Coverage includes: Repair, including parts Calibration Preventive maintenance program On-site/off-site options Other services can be addedKey Performance Indicator60European Car Plant50403020100Jan Feb March April May June July Aug Sep Oct Nov DecFailures 2009 Failures 2010 No. of Preventive Maintenance per month 201014

ToolScan RCMA tool for optimizing assembly tool maintenanceArea of savings Est. SavingsHandle of tool failure cost £ 4 500Rework cost £ 12 500Line slow down-stop cost £ 60 000Tool replacement cost £ 15 000Quality cost £ 14 000POTENTIAL TOTAL COST SAVINGS £ 106 000RCM Operating Cost Savings CalculatorRCM (Reliability Centered Maintenance) is a proven method ofrationalizing and optimizing maintenance costs in manufacturingindustries. With ToolScan RCM we balance maintenance againstthe operational cost of a failure. Based on our extensive toolfailure statistics, we analyze your total operating costs, the toolapplications and the probability of tool failure. With this informationwe create the optimum maintenance program for yourspecific production operation.Customer valuesKey Performance IndicatorFEATUREOptimized PredictiveMaintenance Program.Identify cost drivers relatedto tools in your production.Continuous update ofnew RCM data.BENEFITMinimized downtimehighest productivity.Higher quality and longertool life.Optimize the valueof service.Saving more costs in thefuture.No. of preventivemaintenanceStandard PreventiveMaintenance20052006RCM 2007RCM 2008RCM 2009Powertrain plantMaintenance Program Year Number of failures %32%13%4%2%1,7%RCM 20101,3%15

Outsourcing solutionsFocus on your core businessWe have extensive experience of outsourcing solutions andcurrently have more than 75 on-site workshops.These are examples of the areas we cover: Preventive maintenance, repair and calibration of allbrands and types of tools. Installation and start-up support. Service management system, including developing KeyPerformance Indicators. Line and process support. Back-up tool/equipment and spare parts management. Other customer requests.Some typical KPI indicators used: Turnaround time for repair. MTTR (Mean Time To Repair) MTBF (Mean Time Between Failures) Number of preventive maintenance actionsvs. repair/failure development Root cause analysis Top 5 problem applications with actions Number of scrapped/replaced tools Availability of equipmentCustomer valuesKey Performance Indicators, Fiat, BrazilFEATUREWe take care of yournon-core business.Global experience fromseveral workshops.BENEFITFocus on your corebusiness.We have the experienceto handle it.750Final assembly plantEquipmentAvailability100%Network of specialists indifferent areas.Global certification programfor our technicians.Get the best competence.Same level of servicewherever you are located.number of toolsAvailabilityKey account managementand global agreements.Keep the same quality andservice in all your globalfacilities.0Air Tools Electrical Tools Controllers Cables Accessories0%16

AMD Germany: OutsourcingAMD (Automobilmanufaktur Dresden GmbH) is part of theVW group and produces the VW Phaeton. AMD’s core processconcept is to outsource all service to a few key suppliers.One outsourcing area is industrial services covering: ProductionIT, tool management and production systems, i.e.,conveyor systems, manufacturing systems, vehicle testingsystems and fluid filling systems.Atlas Copco was awarded this contract for 2010 based on itshigh performance in handling the existing tool service andstrong partnership with AMD since 2000.We also developed new concepts around this service to makeit more cost efficient.Our Key Performance Indicators showed shorter failure reactiontime, plant availability, increased productivity and higher teamefficiency using fewer people.Caterpillar US: Building a New PlantCaterpillar® opened a new manufacturing plant in Seguin,Texas, in 2010.Already working in close cooperation with Caterpillar as amuch appreciated solutions provider, Atlas Copco was askedto manage the move of some existing equipment from oneCat® facility to the new plant.The scope of Atlas Copco’s undertaking was to manage theremoval and refurbishment of all handheld and multi-spindletools, including managing subcontractors.The move started in September 2009, and was finalized byMarch 2010.Caterpillar has now hired an Atlas Copco Fastening Specialistto support production optimization.Fiat Brazil: On-site workshopAt Fiat in Brazil we have had a workshop on-site for morethan 10 years. Today there are 11 people running the workshopin two shifts, covering more than 2,000 air and electrictools with related equipment.Typical tasks handled by our team are preventive and correctivemaintenance, consultancy for process variations, back-uptools and spare parts management.As part of the agreement, we also supply a standard set ofKey Performance Indicators: repair statistics, tool availability,MTTR, MTBF and top 10 maintenance and tool problems.“Through the interaction between Fiat and Atlas Copco it waspossible to streamline internal processes, resulting in higherproductivity, efficiency and quality. The interfaces betweenthe companies are handled in a clear, fast and objective manner,always striving for continuous improvement.”Cesar Quinonez, Production Engineering Manager17

Service packages for new equipmentMaximize your new investmentFor improvedproductivitySolve issuesnow – avoidproblems laterEnsuretrouble-freeoperation18

Full coverageprograms andon-site technicianAs close tozero faults aspossibleInvesting in new tools to upgrade an existing production line? Or perhaps you’redesigning, installing and commissioning an entirely new line. In either case Atlas Copco’sspecialists are there every step of the way to help you focus on quality and efficiency.With your production up and running our service programs will help keep you online withminimum interruptions.19

InstallationEnsure trouble-free operationYou can count on a certified Atlas Copco technician to ensurethe highest quality installation and management of both newtools and surrounding equipment. After each installation youreceive an installation report that also suggests improvementsin your production. With our fixed price installation and startupprograms you always know the cost in advance.Customer valuesInstallation Check ListFEATURESet-up of tightening strategyby a certified technician.One provider handles theentire delivery and set-up.Knowledge of the installation.Fixed price installation.BENEFITImproved quality and fullwarranty on the installation.Just one supplier to dealwith and free to focus oncore business.Consultation supportafterwards.Know your costs in advance. Programming and testing of the tool/system I/O’s and PLC connections and functions ToolsNet connections Back-up protocol with a customer copy Cable installation based on Atlas Copco guidelines Handover protocol with a customer copy Other customer specific functions and requests20

Customer trainingFor improved productivityHaving well-trained operators, line engineers and qualitypeople in your operation, ensures optimum tool performance,higher productivity and correct use of your toolsand equipment.Our training also gives your personnel the capability todetermine whether production issues and interruptions arethe result of problems with the tools or with the parts usedin assembly.We have developed an extensive range of training coursesthat are supported from our larger Customer Centersthroughout the world.Customer valuesTypical training programs:FEATUREOperator training.Well trained personal.Better understanding of theequipment.BENEFITReduced tool misuse andabuse.Higher quality.Improved productivity.Higher productivity andquality. Operator training in how to handle andoperate our tools. Tightening Technique at different levels. Joint analysis and process optimization. Software. ToolsNet. Line wrench management. Material removal training. Ergonomic training. Tailor made training programs developed withour customers.22

Production optimizationZero fault production at the lowest total costRight fromthe startControlrelaxation,leakage andfrictionAs close tozero fault aspossibleDetectfaultyjointsCorrectclampforceOne of our core competences is production optimization. We help you to improve productivityin your existing assembly, or in your new production project. We ensure that the focusremains on quality and efficiency from concept/R&D through to full production. Whilebolted joint issues are the common denominator, there are many other factors involved.23

Production optimizationImprove productivity on your existing lineTORQUEANGLESPEEDProgram optimization: Taking advantage of the functionalityof our advanced controllers, our field engineers optimize monitoringand control limits to identify faulty joints.Friction analysis: When quality issues like broken or elongatedbolt are identified, the cause can be frictional changes inthe bolted joint. A laboratory analysis can highlight the rootcause enabling a solution to be found.Joint analysis: If the problem is more complex, a full jointanalysis might be necessary. Atlas Copco has the laboratoryequipment, expertise and software to evaluate the developmentof clamp load in bolted joints, as well as optimizedrundown specifications.Production optimization: Analysis of the entire workstationfrom the perspective of the bolted joint is Atlas Copco’sunique method of optimizing production. It can help raiseproduct quality and achieve cost-effective production.FEATUREProgram optimization.Friction analysis.Joint analysis.Production optimization.Customer valuesBENEFITEnsure quality. Detectproblems in bolted joints.Detect problem bolts.Supplier evaluation.Validation of bolted jointcharacteristics andfunctionality.Optimized productionefficiency and productquality.Production optimization caseA customer assembling compressors for air conditioningsystems had a high reject rate during the finaltest for helium leakages. The total invest for this testwas EUR 800,000/year.The application, consisting of several joints, was auditedby our Production Optimization experts. Duringthe audit some failures in sequencing and thereforerelaxation issues were detected.Our Production Optimization experts developed andintroduced an improved tightening sequence and anew process using the existing robot fixtured nutrunner.After installing the improved tightening process thereject rate dropped to zero. The EUR 800,000 heliumleakage test is no longer necessary since the processcontrol ensures 100% OK tightening results.24

Production optimizationFocus on quality and efficiency in new projectsArea of savings Est. SavingsRework cost $ 8 575Line slow down-stop cost $ 24 500Part replacement cost $ 60 000Recall cost $ 21 000Quality cost $ 22 000Warranty cost $ 17 000POTENTIAL TOTAL COST SAVINGS $ 153 075Production Optimization Cost Savings CalculatorConcept R&D: Actions include – Bolted joint review, clampload and friction analysis, tool accessibility and rundownspecification analysis.Strategy development: Actions include – Bolted joint analysis,SW simulation, joint classification, tool selection, fasteningprocess and error-proofing development.Pilot test: Actions include – Bolted joint analysis, implementationof customized fastening processes and sequences, clampload, frictional and quality validation.Pre production: Actions include – Bolted joint analysis, evaluatingprocess limits, joint analysis, optimizing sequencing,cycle time, bolt relaxation and product qualityFull production: Actions include – Bolted joint analysis, determinationof Cp/Cpk, quality status, overview of assemblypotentials, quality system potentials and ergonomic improvement.FEATUREConcept R&D.Strategy development.Pilot test.Pre production.Customer valuesBENEFITDesign and testing forquality production.Effective and proven fasteningsolutions.Improved station functionalityand production flow.Guaranteed quality from thebeginning.Production optimization caseA clamp load analysis was carried out for a powertraincustomer on a differential gear. Historically theproduct had a high warranty rate since, although theywere tightened to the correct torque, the bolts wouldlose clamp load during normal operation.Our Production Optimization expert performed anultrasonic clamp load analysis on the bolted joints ofthe differential case and ring gear bolts. To achieve thecorrect clamp load and ensure its stability calls for afastening process with the correct program strategyand sequencing.Full production.Measurable efficiency andproductivity.In this case a yield fastening process was developed.Customer savings in warranty costs are estimated atUSD1M.25

Service ProgramsFull coverage programs and on-site technicianDepending on the size of your operation, different serviceprograms are available for your new Atlas Copco equipment.Atlas Copco ToolCover and ExpressCover programs ensuretrouble-free operation for your electric tools.If you have a new plant or larger new production line, anon-site Atlas Copco technician is a recommended option. Wehave long experience of handling new tool and installationissues in an efficient way.Customer valuesWhat is ToolCover?FEATUREFull coverage.Scheduled preventive maintenancewith service book.Inspection of tool/systemwith protocol.Fixed cost.Certified service.Secured tool performance.On-site options.BENEFITPeace of mind.Less downtime, more uptime,fewer failures, lowerlife-cycle cost.Documented quality.Control over yourmaintenance budget.Quality experience.Higher quality in production.Quicker turnaround time. Full coverage option for two or three years. Cover both repairs and parts. Preventive Maintenance program tailored to yourproduction rate. Yearly calibration with protocol. Inspection protocol checking critical points ontools/system Off-site / On-site options.26

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