Tool maintenance and production optimization - Atlas Copco
Tool maintenance and production optimization - Atlas Copco
Tool maintenance and production optimization - Atlas Copco
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Production <strong>optimization</strong>Focus on quality <strong>and</strong> 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 <strong>and</strong> friction analysis, tool accessibility <strong>and</strong> rundownspecification analysis.Strategy development: Actions include – Bolted joint analysis,SW simulation, joint classification, tool selection, fasteningprocess <strong>and</strong> error-proofing development.Pilot test: Actions include – Bolted joint analysis, implementationof customized fastening processes <strong>and</strong> sequences, clampload, frictional <strong>and</strong> quality validation.Pre <strong>production</strong>: Actions include – Bolted joint analysis, evaluatingprocess limits, joint analysis, optimizing sequencing,cycle time, bolt relaxation <strong>and</strong> product qualityFull <strong>production</strong>: Actions include – Bolted joint analysis, determinationof Cp/Cpk, quality status, overview of assemblypotentials, quality system potentials <strong>and</strong> ergonomic improvement.FEATUREConcept R&D.Strategy development.Pilot test.Pre <strong>production</strong>.Customer valuesBENEFITDesign <strong>and</strong> testing forquality <strong>production</strong>.Effective <strong>and</strong> proven fasteningsolutions.Improved station functionality<strong>and</strong> <strong>production</strong> flow.Guaranteed quality from thebeginning.Production <strong>optimization</strong> 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 <strong>and</strong> ring gear bolts. To achieve thecorrect clamp load <strong>and</strong> ensure its stability calls for afastening process with the correct program strategy<strong>and</strong> sequencing.Full <strong>production</strong>.Measurable efficiency <strong>and</strong>productivity.In this case a yield fastening process was developed.Customer savings in warranty costs are estimated atUSD1M.25
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