Assembly

ASSEMBLY
July 2009 www.assemblymag.com
Technology
Makes an
Impact
pg 20
State of the
Profession 24
Bonding a Trailer 38
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July 2009 Vol. 52, No. 7
20
ASSEMBLY 66
COVER STORY 24
䡵
20 Technology Makes an Impact
New technology gives impact wrenches the ability to
measure torque and angle.—John Sprovieri
FEATURES 38
䡵
24 Ready for the Recovery DEPARTMENTS
Our annual State of the Profession survey indicates that
Assembly Lines . . . . . . . . . . . . . . . . . . . . . 15
assemblers are worried, but cautiously optimistic. Cleveland plant to build “green” engines.
—Austin Weber
Assembly in Action . . . . . . . . . . . . . . . . . . 18
䡵
38 Adhesives for Trailer Assembly
Coiled spring pins improve steering assembly.
Moving Forward . . . . . . . . . . . . . . . . . . . . . 19
Structural adhesives help assemblers of trucks, trailers, Sun rises on new plant for making solar panels.
buses and other specialty vehicles reduce costs, boost —John Sprovieri
40 throughput and improve aesthetics.—Brian Noonan
Product Reviews . . . . . . . . . . . . . . . . . . . . 42
In-depth profiles of the latest assembly technology.
Classified . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Case Studies in Assembly . . . . . . . . . . . . 48
Learn how our advertisers have helped
assemblers solve problems.
DEPARTMENTS Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Whose back yard?—Don Hegland Advertisers Index . . . . . . . . . . . . . . . . . . . . 63
Automation Profiles . . . . . . . . . . . . . . . . . . 8 Leading Lean . . . . . . . . . . . . . . . . . . . . . . . 64

Systems integrator builds mousetraps better.—John Sprovieri
New & Noteworthy . . . . . . . . . . . . . . . . . . 12
Ultrasonic gripper picks up wafers without touching them.
We Fed It . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
One bowl is better than two.—John Sprovieri
NEXT MONTH
Selective Soldering
Automating Battery Assembly
Cover photo courtesy Atlas Copco Tools & Assembly Systems Equipment for Spraying Dots
What’s New in Linear Actuators
2 ASSEMBLY / July 2009 www.assemblymag.com

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Editorial ASSEMBLY ®
1050 IL Route 83, Suite 200

Bensenville, IL 60106-1096
Phone 248-362-3700
Fax 630-227-0204
Whose Back Yard?

TOM ESPOSITO
E
veryone knows NIMBY. “Not in my backyard” Publisher
succinctly describes our reaction to anyone’s proposal espositot@bnpmedia.com
to locate anything we find objectionable in close BILL DEYOE
proximity to where we live, work or play. Associate Publisher
deyoew@bnpmedia.com
In the case of obsolete computers, TV sets, cell phones
and myriad other electronic products discarded for DONALD E. HEGLAND
Editorial Director
recycling and reclamation, the challenge of how to safely heglandd@bnpmedia.com
dispose of them has become a major NIMBY issue. In a JOHN SPROVIERI
podcast last year, IBM pointed out that the fastest-growing Editor
part of the waste stream is electronic products. In 2007 sprovierij@bnpmedia.com
alone, more than 63 million computers in the United AUSTIN WEBER
States were traded in or thrown out, according to the Environmental Protection Senior Editor
webera@bnpmedia.com
Agency (www.ibm.com/podcasts).
ADAM CORT
IBM has long focused on recycling its own information technology products. Senior Editor
Its take-back programs began in Europe in 1989, and IBM now offers asset- corta@bnpmedia.com
recovery programs in 57 countries. Between 2002 and 2005, the company’s asset MIKE ROBINSON
disposition operations took in and reused more than 1.9 million machines. Art Director
robinsonm@bnpmedia.com
Panasonic, Sharp and Toshiba recently founded an organization—the Electronic
Manufacturers Recycling Management Co. LLC (www.mrmrecycling.com)—to AMANDA PODINA
Marketing Coordinator
help recycle televisions and other electronic equipment they sell in the United podinaa@bnpmedia.com
States. The company will administer a nationwide network of 280 locations as
LISA WEBB
collection centers for their products. Production Manager
Similarly, Sony, Best Buy, Hewlett Packard and Office Depot are creating webbl@bnpmedia.com
programs for people to recycle old electronic products. Best Buy has a Tech CAROLYN PERUCCA
Trade-in program in which people can bring in their used electronics and receive Buyers Guide Project Leader
peruccac@bnpmedia.com
a store gift card.
We all live on this planet together, so it behooves us to do all we can to develop CINDY WILLIAMS
Corporate Reprint &
practical solutions to the challenge of disposing, recycling and reclaiming Trade Show Coordinator
parts of obsolete electronics equipment. What are your options? The Rethink williamsc@bnpmedia.com
Initiative (http://pages.ebay.com/rethink/index.html) brings industry, government
and environmental organizations together to offer a fresh perspective and new
CORPORATE DIRECTORS
answers to the challenge of e-waste. One of the initiative’s members, eBay, is
encouraging everyone in its community of more than 157 million members to use Publishing Timothy A. Fausch
eBay to find homes for any idle computers they might have. Publishing David M. Lurie
IBM has long suggested that you donate or recycle your old desktop instead of Publishing John R. Schrei
trashing it. If it’s less than five years old, your computer can probably be put to Audience Development Christine A. Baloga
good use by a school or charity. Otherwise, the best option is recycling. To find Custom Media Steve M. Beyer
a recycler near you, visit the National Center for Electronics Recycling web site, Corporate Strategy Rita M. Foumia
Information Technology Scott Kesler
www.electronicsrecycling.org.
Production Vincent M. Miconi
The same suggestions apply to TV sets, cell phones and other electronic Finance Lisa L. Paulus
products. For example, shelters for battered women are always eager to receive Creative Michael T. Powell
cell phones because most are capable of making 911 calls, even without a service Marketing Jennifer Acevedo
contract. Homeless shelters are a good bet for TV sets. The possibilities are Directories Nikki Smith
limited only by your imagination and willingness to seek them out. Human Resources Marlene J. Witthoft
Whose backyard? Everyone’s backyard! Conferences & Events Scott Wolters
Clear Seas Research John Thomas
BNP Media Helps People

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Automation
Profiles
Systems Integrator
Builds Mousetraps Better
The dial assembles 900 traps per hour.
S
ince the U.S. Patent Office opened for business in 1838, it has granted more than
4,400 patents for mousetraps.
Systems integrator Isthmus Engineering & Manufacturing (Madison, WI) can’t
lay claim to building a better mousetrap. However, it can boast that it found a way to build
mousetraps better. Recently, the company designed a system that automatically assembles
and packages mousetraps. The traps are assembled on a rotary indexing dial and then
transferred to an automated packaging station.
In this profile, sales engineer Jane Feller rats out the system’s secrets. For more infor-
mation, call 608-222-9000 or visit www.isthmuseng.com.
What are the dimensions of the finished assembly? The trap is 3.25 inches by 1.75
inches. The traps are sold in packages of two. The package is approximately 6 inches by
5 inches by 2 inches.
How many parts are assembled? The trap has four parts: the top, bottom, actuator
and spring.
What are the parts made of? The top, bottom and actuator are plastic. The spring is
a coil-steel extension spring. The packaging is card stock.
At the packaging station, mousetraps are loaded two-up What equipment feeds the parts? All four parts are fed from vibratory bowls and
onto card stock, which is then folded, glued and placed feed tracks to pick-and-place stations, where they are placed into fixtures around the
on a belt conveyor. Photo courtesy Isthmus Engineering perimeter of the indexing dial. A SCARA robot transfers the assemblies from the dial
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to a linear indexer, which guides them to the Can the system accommodate product
packaging station. There, they are loaded two- variants? The machine was not designed for
up onto the card stock, which is then folded, large variants or different products without
glued and placed on a belt conveyor to exit the retooling. However, the packaging station is
system. completely adjustable to accommodate varia-
What methods are used to assemble the tions in card stock.
product? The parts assemble with snap-fits. What was the most challenging aspect
The packaging is folded with a custom servo of designing and building the system?
system and bonded with hot-melt adhesive. Custom folding the packaging was quite
What checks or inspections are included a feat. The packaging is a custom design.
in the assembly process? Each assembly Maintaining perfect bend angles and align-
station is equipped with photoelectric sensors to ment was done with coordinated servo and
check that parts are present. Before the finished pneumatic positioning. This took a little de-
assemblies are transferred to the linear indexer, bugging and testing on our assembly floor,
a custom-tooled unit sets and actuates each trap but the result was a robust and accurate
to ensure that it works correctly. The SCARA packaging station. A
robot sorts rejected assemblies by category or All four parts for the mousetrap are fed from
places good assemblies into fixtures on the vibratory bowls and feed tracks to pick-and- Editor’s note: Whether you’re a systems
linear indexer. place stations. The parts assemble with snap- integrator or the inhouse automation team
What is the production rate? The dial fits. Photo courtesy Isthmus Engineering of an OEM, if you’ve designed a system that
assembles 900 traps per hour. The packaging product for efficient automated assembly? you’re particularly proud of, tell us about it.
station produces 450 retail-ready packages per Some of the snap-fit lead-ins and chamfers Send an e-mail to John Sprovieri, editor of
hour. were adjusted in their dies to accommodate ASSEMBLY, at sprovierij@bnpmedia.com, or
How did you help the customer design the automated assembly. call 630-694-4012.
ROBOTIC END EFFECTORS
Why ATI sells more Superior Fail-Safe—springless design

maintains lock position in event of air
Robotic Tool Changers pressure loss
than anyone else

in the world.
Specially Tapered Cam—second taper
produces high locking strength
Locking Balls—Low-friction locking

balls extend the life of the unit
Lock Ring—Wide footprint of lock ring creates

high moment capacity in locking mechanism
• Wide-diameter locking mechanism and specially tapered cam produce high

coupling strength and large moment capacity, which eliminates gapping.
• Superior mechanical fail-safe keeps tool locked to master plate in the
event of air pressure loss—without a spring. This no-spring design
www.ati-ia.com/qc/
eliminates unlock problems. 919.772.0115
• Engineered for long life—patented double-taper lock wears in, not out.
Million-cycle tested for high repeatability.
www.assemblymag.com July 2009 / ASSE M B LY 9

NEW & NOTEWORTHY
Robot Offers Speed, Vision Capability
Cap
The M-1iA assembly robot is a lightweight, compact six-axis, parallel-link
RED robot designed for small part handling, and high-speed picking and assem-
bly applications. The robot can be installed in a variety of orientations and
has a three-axis wrist, making it extremely flexible. It is also available with
a single-axis wrist for less complicated applications requiring ultra-high
HOT
speeds. The system is preconfigured for use with the new R-30iA control-
ler. It can accommodate both a collision guard function and advanced
machine vision. Its small size means it can be used in areas where space is
at a premium and easily integrated into a larger assembly system.
FANUC Robotics
Leak Detection 800-iQ-ROBOT
www.fanucrobotics.com
Pfeiffer Vacuum's SmartTest™ is a

rugged, easy to use helium leak detector
offering an Industry Best Warranty.
Monitor Higher Torques
High-capacity Torque Functional Test (TFT) system line includes three
new models ranging from 500 Nm to 2,500 Nm. In addition to their
highly accurate positioning capabilities, the new TFT units offer one
percent fullscale torque sensor accuracy and 0.25 percent torque sensor
repeatability. The systems offer speeds up to 200 rpm and can be tailored
to an assembler’s particular needs with a full range of customized features
and standard options. Each TFT includes both servomotors and precise
position sensors to monitor and control torque inputs when installing
fasteners, and performing pressing operations and functional tests during
and after assembly.
Promess Inc.
3 year Ion Source and Filament warranty
810-229-9334
Lowest detectable leak rate for helium — www.promessinc.com
5 x 10-12 mbar l/sec
High inlet pressure of 25 mbar
Easily configured to your application
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Narrow Profile Slides Carry Heavy Loads
The narrow-profile Slide 2 system is constructed from a single rigid
aluminum extrusion to carry heavy loads. It is only 75 millimeters wide,
but capable of carrying loads of up to 250 pounds. Available with single
or dual carriage options, the device can attain speeds up to 24 inches
per second, depending on the motor and drive package. Other options
include a stepper motor or servomotor mounted either to the side or in-
line. Each slide incorporates a pair of precision steel rails, bearing blocks
and a 16-millimeter anti-backlash ball screw drive to ensure accuracy
and durability. The slides can be ordered in lengths up to 107.2 inches.
Techno Inc.
800-819-3366
www.technoautomation.com
Noncontact Gripper Handles Fragile Parts

This ultrasonic gripper can pick and place solar cells, wafers and other
fragile parts without ever touching them. The gripper works on the
principle of near-field levitation, in which an ultrasonic generator creates
a thin film of pressurized air between the gripper and the workpiece at
the same time air is extracted through holes on the gripper face creating
a vacuum. Basically, the vacuum holds the workpiece while the pressure
created by the ultrasonic waves keeps it at a short distance, so that it
and the gripper never come in actual physical contact. The distance
between the ultrasonic gripper and workpiece can be between 0.05 and
0.5 millimeter.
Schunk Inc.
800-772-4865
www.schunk.com

WE FED IT
One Bowl Better Than Two

䡲 By John Sprovieri
Editor
S
ometimes, it’s the machine you don’t sell that wins you
business.
That was the case for Mike Stamm, general manager of Custom
Feeder Co. (Rockford, IL). Recently, an ammunition manufacturer contacted
Stamm to build two vibratory bowls to feed 9 mm pistol cartridges at a rate
of 120 parts per minute.
One bowl needed to feed the cartridges with the open end trailing,
so an ejector groove could be machined around the cartridge body. The
other bowl had to feed the cartridges with the open end leading, so the
parts could be cut to length. Since both operations would be performed
on the same machine, a complicated slide mechanism would switch
from one bowl to the other.
Stamm had a better idea. Why not build one bowl to handle both jobs?
Stamm and his team built a bowl with an inside track that feeds the cartridges
Equipped with quick-change tooling, this bowl can feed cartridges upright, with the open end up. As the track winds to the outside of the bowl,
with the open end leading or trailing. Note how the tooling to feed it encounters a set of quick-change tooling that tips the cartridges forward or
the cartridges in the opposite direction is stored on the bowl itself. backward. Two bolts hold the tooling in place.
Photo courtesy Custom Feeder Co. “We avoid adjustable tooling whenever possible, because we don’t want
Editor’s note: “We Fed It” is a regular series profiling parts feeders operators to dial in any parameters,” says Stamm.
for automated assembly. Whether it’s a vibratory bowl, a tray feeder Changeover takes less than two minutes, and the bowl feeds 160 cartridges
or a flexible robotic system, if you’ve solved a parts-feeding challenge, per minute. In another bit of clever engineering, the opposite set of tooling is
we’d like to hear about it. Send an e-mail to John Sprovieri, editor of stored on the bowl itself, so operators never waste time looking for it.
ASSEMBLY, at sprovierij@bnpmedia.com, or call 630-694-4012. For more information, call 815-654-2444 or visit www.customfeeder.com. A
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Assembly Lines
Inventions
Forecasts
Mergers
New facilities
Hegland Retires Boeing: Long-term
Cleveland Plant First to as ASSEMBLY’s Prospects
Build ‘Green’ Engines Editorial Director Remain Good
BENSENVILLE, IL—After CHICAGO—Despite the current
nearly 25 years at the helm of hard times, Boeing Co. projects that
ASSEMBLY magazine, Donald in the long term, the demand for
E. Hegland has retired. airplanes will remain strong, with
airlines buying an estimated 29,000
new commercial airplanes valued at
$3.2 trillion over next 20 years.
In its annual market outlet report,
now in its 45th year, the company
also predicts that global passenger
traffic will grow about 4.9 percent
annually over the next two decades,
and that cargo traffic to grow at an
average annual rate of 5.4 percent.
“While the commercial avia-
tion industry is facing a signifi-
cant downturn, it is cyclic and
Ford Motor Co. has begun assembling its new EcoBoost Engine in has a long history of declines and
its retooled Plant No. 1 in Cleveland. Photo courtesy Ford Motor Co. upturns,” says Boeing vice presi-
John Sprovieri, who joined the dent of marketing Randy Tinseth.
DEARBORN, MI—Ford Motor Co. recently marked what it de- magazine as a senior editor in Feb- “Over the past 30 years, through
scribes as a “key step” in its plan to provide fuel economy across its ruary 1997, will continue as the both tough and good times, traffic
product line by beginning production of the new EcoBoost engine publication’s chief editor. growth has averaged more than 5
at its Engine Plant No. 1 in Cleveland. Hegland joined the magazine percent per year, demonstrating
To facilitate the changeover, Ford invested approximately $55 in July 1985, and he will continue the resilience of the market.”
million to retool the facility, which was idled in 2007. Approxi- to contribute to ASSEMBLY According to the report, small-
mately 250 employees have returned to work to build the new en- as editorial director emeritus. er single-aisle airplanes, like the
gines, which will be available in the 2010 Lincoln MKS and Lin- Beginning in September, he’ll Boeing 737 and Airbus A320,
coln MKT. be writing a new bimonthly will represent 67 percent of all
EcoBoost engines combine turbocharging and direct gasoline in- column in ASSEMBLY to share sales in terms of units. Larger
jection to provide better fuel economy and reduce carbon dioxide his thoughts on current events in twin-aisle airplanes, like the new
emissions, at the same time improving performance. According to manufacturing. Boeing 787 Dreamliner and the
Ford, this “downsize and boost” strategy provides consumers better Prior to joining ASSEMBLY, Airbus A380, will capture the
fuel economy in a smaller engine without sacrificing power. Hegland served as chief editor of largest market share in terms of
“This launch of the first EcoBoost engine is a significant mile- Production Engineering magazine investment dollars.
stone in Ford’s overall commitment to deliver affordable fuel effi- and publisher of Industrial Paint &
ciency for millions,” says Barb Samardzich, vice president of global Powder magazine. Before entering
powertrain engineering. “We’ve spent the past two years developing the publishing profession, Hegland
EcoBoost technology and now our customers will finally have the was an engineer with NASA. He Norfolk Southern
opportunity to experience what this engine delivers, the power of a holds a bachelor’s degree in physics Earns Logistics
V-8 with the fuel economy of a V-6.”
Ford’s Cleveland Engine Plant No. 1 opened in 1951 as the com-
from Northern Illinois University
in DeKalb, IL, and a master’s
Excellence Award
pany’s first engine plant in Ohio. Since then it has produced more degree in physics from Iowa State NORFOLK, VA—UPS Auto-
than 35 million engines. University in Ames, IA. gistics (Atlanta), in conjunction

Assembly Lines
Grow by Developing Within

Eric Bigelow
Industrial Engineer–Continuous Improvement
Yamaha Motor Manufacturing Corp. of America
Newnan, GA
There are thousands of articles and books on promoting from with-

in a company. There are an equal number on employee development.
But how many companies actually strive for it? How many companies
invest time and capital into every single employee? How many man-
agers measure the promotability of their people and grade themselves
on the outcome?
Some managers believe in forced attrition, in which they remove 10
percent to 15 percent of the workforce every year to recruit new talent
from outside the company. This theory does have several convincing
arguments. Hiring from outside will bring with it fresh ideas and new
technologies. It will bring expertise and solutions. Nevertheless, prac-
ticing this theory will not produce the long-term sustainable benefits
most companies crave. It will, in fact, have an opposite effect.
Sometimes hiring from outside the company is a necessity. It is
good to have new talent come into the company. However, it should
only be encouraged at a company’s beginning stages, or during a new
production system’s design or implementation. In other words, hiring
from outside should only be a necessity as a robust, healthy production
system is being created. Once the system is up and running, manage-
XYZO~ ment should make a collective effort to avoid it.
How can management avoid it? The answer is, by avidly invest-
Robotic ing in employees. Many managers fail to realize that the talent they
are chasing outside the company is already inside, waiting to demon-
System strate its value. Everyone has enthusiasm when they start a new career.
Everyone wants to make a good impression and show their value to
Automatically
Identifies, with Ford Motor Co. (Dearborn, Promess Inc.
Locates, MI), has presented Norfolk South-
Registers, ern Railway with its 2008 Carrier
Marking Quarter
and Drives of the Year Award for overall lo- Century
gistics excellence in the transpor- BRIGHTON, MI—Industrial
tation of Ford vehicles. pressing, sensing and torque
t%SJWFT.VMUJQMF
The award recognizes superior equipment manufacturer Promess
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performance in on-time delivery, Inc. is marking 25 years in busi-
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damage-free handling and total ness by preparing to move ahead
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customer service. Norfolk Southern with yet another expansion of its
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transported more than 1.4 million office, research and manufacturing
t$BOCF7JTJPO
Ford vehicles in 2008. facility in Southeast Michigan.
(VJEFE 3PUBSZ*OEFYFE
“Ford and Norfolk Southern Incorporated in 1984, Promess
t5IFUB"YJT
have had a long, mutually beneficial moved into its current head-
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relationship, and this award is a quarters in 1986, subsequently
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testament to their commitment expanding the facility in 1991
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to excellence and customer and again in 1998 to its present
service,” says Walter Lowe, Ford’s 25,000 square feet. Plans and
sales@visumatic.com manager for North America vehicle permits for a third proposed ex-
www.visumatic.com logistics. pansion are already complete
859.255.7907 In all, Norfolk Southern Railway and will be implemented as
operates approximately 21,000 market conditions improve, says
route miles in 22 states and the Dis- company founder and president
trict of Columbia, and serves every Larry Stockline.
major container port in the eastern Upon completion, the upgrade
United States. will increase the facility’s

The SCHMIDT
Solution
their superiors. Therefore, start developing employees at this stage—
keep the enthusiasm alive and keep up expectations. SCHMIDT®
ServoPress For Absolute
Train all employees in the company’s production system. Give
them improvement projects and coach them to guarantee successes. Systems Press Control
Send employees to lean seminars and schools. Invest until they are • Fully integrated, & Real Time
filled with system values and theories. Invest until they have passion self-contained
system Feedback
and experience. Then measure them on their lean decisions and
actions. Promote based on the mastery of elements designed into a • Closed loop
career path. control of ram
Creating a robust production system will naturally create a career force and
distance
path for employees. It will naturally call for employee development,
empowerment and measurables. It will give employees the enthusiasm • Positioning
to learn the production system and grow within it. Management will accuracy of .0004”
be able to create and mold talent as it needs it. The company will then • Dynamic bending
have an army of lean thinkers and doers already built to its specifica- compensation
tions and requirements. Managers will have employees who are ready • 100% quality
to take on new responsibilities at a moment’s notice. assurance and
If employees are neither challenged nor developed, their perfor- verification
mance will eventually decline and stagnate. This is why managers so
often find themselves having to resort to recruiting from the outside,
because the enthusiasm of their existing employees has plummeted.
The manager missed the window. Worse yet, without a robust system, ®
the new recruit’s enthusiasm will also plummet over time, creating a
vicious cycle that costs the company valuable time and money.
Imagine having an entire workforce devoted to the company’s one, Call 1-800-959-1218
robust, lean manufacturing system, dedicated to the elimination of Visit: www.schmidtpresses.com
waste. Picture every employee working to be the best and the most
promotable. Imagine all your employees absorbing as much as they can
from lean experts and then applying those theories every day at work.
Visualize having a workforce flexible enough to handle any situation,
capable of being promoted into almost any position at a moment’s
notice. Employees can and will do all this for the management team—
The SCHMIDT
asb01094schmidt1.indd 1 12/17/08 10:13:30 AM
all it takes is time and investment. Solution

production capacity about 40 as a “new portfolio of globally SCHMIDT®
percent. Promess also has a structured service products,” to For Cost Effective
ManualPress
plant in Berlin, Germany, which help its customers get the most 300 Series Assembly
manufactures products for out of their wire processing • Versatile, with 100% QC
distribution outside the United equipment. hand-powered and Stroke
operation with
States. Specific products include in- process monitoring Control
The Promess equipment line vestment and presales support,
is comprised of “intelligent” sys- commissioning at the customer
• Sequence/Monitor
controller
tems that both monitor and control site, a preventive maintenance • Electronic stroke
manufacturing and assembly pro- and extended warranty pro- control via clutch
and brake
cesses by measuring in-process gram, and new options for re-
assembly or functional force, po- pair services. • Rack & Pinion and
Toggle Press
sition and torque to ensure that the Regular preventive mainte- models
resulting components are within nance, in particular, will not • Integrated load
specification. only extend the life of a piece cell and linear
scale
of equipment, but ensure it pro-
duces the highest quality prod- • “Poke Yoke”
process verification
uct. The company’s maintenance
Schleuniger service includes cleaning, lubri-
Launches Service cation, calibration, the exchange
Products of a system’s most important
wearable items and software up-
®
MANCHESTER, NH—Wire grading.

processing equipment manufac- For additional information, vis-
Call 1-800-959-1218
turer Schleuniger USA recently it www.schleuniger-na.com or call
unveiled what it is describing 603-668-8117. Visit: www.schmidtpresses.com

Assembly in Action
Coiled Spring Pins Improve

Steering Column Assembly
A
t its plant in Hamburg, Ger- Because the new pins provide the
many, Daimler AG (Stuttgart, same shear strength as the original, they
Germany) recently decided to saved Daimler from having to perform
further streamline its manufac- a new set of validation tests. The end
turing processes with respect result was improved productivity and
to one of its steering column fewer scrapped assemblies.
assemblies. Specifically, the company Once assembled, the pin, which
discovered that the phosphate-coated functions like a hinge, is subject to
coiled pins it was using to attach minimal loads. This meant Daimler
the system’s aluminum housing had the option of going with a lighter-
and gear motor were failing dur- duty pin of similar design. However,
ing installation because of the doing so would have required running
high insertion forces required. a full set of new validation tests, so the
The result was an unacceptable company chose to go with the sturdier
amount of scrap and decreased configuration.
productivity due to the down
time required to continually fix The fasteners help isolate the
the problem.
Because the steering column assemblies in which they are
was already a mature design,
the hole sizes could no longer be
installed from shock loads and
changed without incurring unac- vibration.
ceptably high engineering and re-
validation costs. In addition, the During installation, a coiled spring
customer had already invested in pin is compressed so that it will fit
an expensive automated assem- easily in a hole, or holes, and then
bly system configured to insert allowed to relax once in place. It is this
the original pins within a specific inherent flexibility that enables coiled
force range. pins to absorb wide manufacturing
To solve the issue, Daimler tolerances as well as provide self-
switched to a controlled-inser- retaining performance. In operation, the
During installation, a coiled spring pin tion, standard-duty pin from fastener fasteners serve as a kind of “mini shock
is first compressed so that it will fit and installation equipment manu- absorber,” in that they help isolate the
easily in a hole. It is then allowed to
facturer Spirol International Corp. assemblies in which they are installed
relax once in place.
(Danielson, CT). from shock loads and vibration. The
Because of their superior quality, pins provide a uniform radial force
the Spirol coiled pins required against the surfaces of the holes in
far less insertion force than what which they are installed across 270
Daimler had been using previously, degrees of contact. They do not require
For reprints of any thereby allowing the company to tight hole tolerances and easily lend
Assembly in Action article, avoid damaging the columns’ housing themselves to automated installation.
please contact Cindy Williams assemblies. Spirol also recommended For additional information on
at williamsc@bnpmedia.com that the phosphate coating be removed pins and mechanical fasteners, call
or 610-436-4220 ext. 8516. to help cut materials costs. 860-774-8571 or visit www.spirol.com.

Sun Rises on New Plant
for Making Solar Panels
䡲 By John Sprovieri
Editor
D
awn may have finally broken for the photovoltaics industry.
Design breakthroughs, government initiatives and the rising
price of fossil fuels are spurring demand for products that har-
ness the sun’s energy. Across the country, promising new companies
are racing to open manufacturing facilities to take advantage of this
emerging market.
Ascent Solar Technologies Inc. is a case in point. In March, the
company opened its new headquarters in Thornton, CO. Expected to
hire some 200 people during the next two years, the facility was built
to launch full-scale production of thin-film photovoltaic modules.
Ascent Solar was formed in October 2005 by ITN Energy Sys-
tems, a technology incubator that has applied more than $60 million
to research and development in photovoltaics over the past 15 years.
Unlike conventional solar panels, which consist of silicon solar cells Ashutosh Misra, Ascent Solar’s senior vice president, shows off a
sealed under large, rigid glass panels, Ascent Solar’s thin-film mod- machine for applying CIGS to a thin polyimide film in a roll-to-roll
ules are lightweight and flexible. With an efficiency of 9.5 percent, the process. Photo courtesy Ascent Solar Technologies Inc.
modules can power spacecraft, consumer electronics, and residential cells. “Essentially, our process creates the world’s largest solar cell—
and commercial buildings. it’s the length of the entire substrate,” explains Blackman.
The company began producing the modules in late 2007 at its origi- In the first step, a machine applies a thin layer of molybdenum to
nal plant in Littleton, CO. “The most challenging thing for us was the plastic. This layer helps collect the electrons generated by the pho-
going from the R&D lab to pilot production,” says Brian Blackman, tovoltaic material. The next machine applies layers of copper-indium-
investor relations manager for Ascent Solar. “The equipment we’re gallium-diselenide (CIGS) in a thermal evaporation, vacuum deposi-
installing for full-scale production is identical to the equipment we tion process. A window, or buffer, layer is deposited next, followed
developed for pilot production. It has taken a lot of time and work to by a transparent conductive oxide. In the next steps—monolithic inte-
debug pilot production, but that will save time when we’re ramping gration, screen printing and laser scribing—additional conductors are
up the new line.” applied to the modules.
To get its new headquarters, Ascent purchased an existing 120,000 After the modules are cut to length, they are laminated with a pro-
square foot structure for $5.35 million. It then spent $10 million on tective plastic. Finally, the finished modules are tested to see how ef-
renovations, adding 20,000 square feet. It spent another $110 million ficiently they turn light into electricity.
on capital equipment. “We upgraded the whole building—everything “Because of our highly automated manufacturing processes, we can pro-
from the power cables to the water lines,” says Blackman. duce the best product at a very competitive price right here [in the United
At peak capacity, the new facility will produce enough solar panels States],” says Mohan Misra, founder and CEO of Ascent Solar. A
in one year to generate 30 megawatts of electricity. In contrast, the
company’s pilot line can only produce enough solar panels annually Editor’s note: With all the news of bailouts, layoffs and plant
to generate 1.5 megawatts. closings, it’s all too easy to think every manufacturer is stuck in the
The process of making Ascent’s photovoltaic modules begins with doldrums. In fact, there’s plenty of good news in manufacturing—if
a roll of high-temperature polyimide film, approximately 330 centi- you take the time to look. “Moving Forward” is dedicated to new
meters wide and 150 meters long. The film passes through a series of or expanding assembly plants. If you know a facility that’s opening,
deposition steps in a roll-to-roll process. growing, investing in new equipment, or simply going great guns
Most solar modules are made up of dozens of individual, intercon- while everyone else is treading water, we’d like to hear about it. Send
nected photovoltaic cells. Ascent Solar’s modules are monolithically an e-mail to John Sprovieri, editor of ASSEMBLY, at sprovierij@
integrated, meaning the company skips the process of connecting bnpmedia.com, or call 630-694-4012.

ASSEMBLY Power Tools
Technology
Makes an Impact
New technology gives impact
T
he impact wrench is hardly anvil is connected to the driveshaft of the
new. In fact, this year marks tool. When the fastener is running free,
wrenches the ability to the 75th anniversary of the
introduction of the impact
the hammer and anvil move together.
When the socket encounters resistance
measure torque and angle. wrench by Ingersoll Rand in from the fastener, the hammer rotates
1934. independently, striking the anvil once or
That’s a good long run for twice with each revolution of the output
any product, much less one for shaft, depending on the tool.
tightening threaded fasteners.
Deanna Carter, global product
manager for industrial and garage
“The impact wrench
tools at Ingersoll Rand Industrial gives you a lot of
Technologies (Annandale, NJ),
thinks she knows why the tool speed and power in
has been around for so long.
“It’s so simple,” she says. “The a small, lightweight
impact wrench gives you a lot
of speed and power in a small, package.”
lightweight package.”
Assemblers shouldn’t con-
—Deanna Carter,
fuse longevity with stagnation,
however. The impact wrench on
Ingersoll Rand
today’s assembly lines is not the “If you need to drive a nail into
same the tool that automotive a piece of wood, you don’t push on
mechanics have been using to it with a continuous force,” explains
bang down lug nuts for decades. Carter. “You pound it in with a series of
New technology has made the impacts. The momentum of the swinging
tools lighter, quieter and more hammer drives the nail through. An
durable. Cordless models have impact wrench works in much the same
been available for a few years way.”
now, and new technology has Because impact wrenches apply
recently been introduced that torque to the fastener in short bursts,
gives impact wrenches the abili- reaction force is minimal, even when
ty to measure and control torque applying hundreds of foot-pounds of
Cordless impact wrenches are more and angle. torque. This design also means that
maneuverable than air-powered tools, but
As its name implies, an impact impact wrenches have a very high
pneumatic tools are faster and more powerful.
Photo courtesy Ingersoll Rand wrench delivers torque in a series of power-to-weight ratio. For example,
Industrial Technologies short bursts created by the impact of the LMS 37 impact wrench from Atlas
a swinging hammer on an anvil. The Copco Tools and Assembly Systems
By John Sprovieri hammer is connected to the output shaft (Auburn Hills, MI) weighs just 6
Editor of a pneumatic or electric motor. The pounds, but it can deliver as much as
352 ft-lbs of torque.
These advantages make impact
wrenches ideal for tightening large
fasteners in products such as heavy
trucks, agricultural equipment,
construction machinery and railcars.
Impact wrenches come in a wide
range of sizes, from a 1/4-inch hex
drive, pistol-grip model to a 3.5-inch
square drive, two-handled behemoth.
The former weighs 2.4 pounds, has
a free speed of 15,000 rpm, delivers
1,500 impacts per minute, and applies
a maximum torque of 250 ft-lbs. The
latter weighs 599 pounds, has a free
speed of 295 rpm, delivers 500 impacts
per minute, and applies a maximum
torque of 80,000 ft-lbs.
Impact wrenches are available in Stanley Assembly Technologies has introduced the first impact wrench with an electronic torque
pistol-grip, in-line and D-handled transducer. Photo courtesy Stanley Assembly Technologies
models. The end of the driveshaft can delivers a maximum torque of 180 ft-lbs. A pistol-grip pneumatic impact wrench
be hexagonal, square or splines. In contrast, Ingersoll Rand’s Model with a 1/2-inch square drive produces a
Industrial-quality cordless impact W150 14.4-volt cordless impact wrench noise level ranging from 89 to 96 deci-
wrenches were introduced in 2006 with a 3/8-inch square drive has a free bels. A D-handled tool with a 1-inch
and are now produced by Ingersoll speed of 2,200 rpm and delivers 3,000 square drive produces a noise level
Rand, Milwaukee Electric Tool Corp. impacts per minute. It weighs 5 pounds, ranging from 94 to 110 decibels. In con-
(Milwaukee) and Makita USA Inc. (La including the battery pack, and delivers trast, a pulse tool generates a noise level
Mirada, CA). For example, Ingersoll a maximum torque of 150 ft-lbs. of 80 decibels, a pneumatic nutrunner
Rand offers cordless impact wrenches with an automatic shut-off clutch pro-
in 7.2-, 14.4- and 19.2-volt models Ergonomic Concerns duces a noise level of 77 decibels, and a
equipped with nickel-cadmium or Although impact wrenches apply a DC electric nutrunner produces a noise
lithium-ion batteries. Drive sizes range lot of torque with little reaction, there level under 70 decibels.
from 1.4-inch hex to 1/2-inch square. To are trade-offs. One is excessive noise. On Ingersoll Rand’s new Max line
reduce weight, the housing is made of impact tools, “we changed
from an engineered composite the air porting and used different
with a metal subframe. materials in the exhaust to make
“With an air tool, you’re the tools quieter,” says Carter.
limited by the air hose in terms Another trade-off is excessive
of what you can reach,” says vibration. According to a 2007
Carter. “You also need access to study conducted by the National
a compressor. The portability of Institute for Occupational Safety
cordless tools is very attractive to An impact wrench delivers and Health (NIOSH, Washington,
a lot of manufacturers.” torque in short bursts created DC), the handle of an impact
On the other hand, pneumatic by the impact of a swinging wrench vibrates with an average
impact wrenches have fewer hammer on an anvil. The acceleration of 6.6 meters per
hammer is connected to the
moving parts than their cordless output shaft of the motor.
second squared. In comparison,
cousins and will typically be The anvil is connected to the a pneumatic nutrunner with an
lighter and more powerful driveshaft of the tool. When automatic shut-off clutch vibrates
than comparably sized battery- the fastener is running free, at 2.5 meters per second squared.
powered tools, says Carter. For the hammer and anvil move A pulse tool vibrates at 2.1 meters
together. When the socket
example, Ingersoll Rand’s 2900 encounters resistance, the
per second squared.
series pneumatic impact wrench hammer rotates independently, To avoid cumulative trauma
with a 3/8-inch square drive striking the anvil once or twice disorders, NIOSH advises
has a free speed of 10,000 rpm with each revolution of the assemblers to avoid operating
and delivers 1,500 impacts per output shaft. Photo courtesy impact wrenches for more than
Chicago Pneumatic
minute. It weighs 2.5 pounds and 4.5 hours per day.
Power Tools
“Impact wrenches should or hits, have been applied to the
not be used for high-volume fastener. “You can set the dial to
assembly,” admits Hans Mandahl, deliver, say, 10 hits and then shut
product manager for assembly off the air,” explains Mandahl.
tools at Atlas Copco. “If you have “That eliminates a lot of operator
to use an impact wrench for 8 influence.”
to 10 hours per day, it could be In the tool crib, engineers can
harmful.” run experiments to correlate a
specific number of hits with the
New Technology desired torque level. “If the torque
Until recently, another trade-off is too low, then you increase the
with impact wrenches has been number of blows on the dial and
torque control and accuracy. In measure again,” says Mandahl.
most cases, the assembler would Stanley Assembly Technolo-
simply hold the trigger until gies (Cleveland) has introduced
he judged the fastener was tight the first impact wrench equipped
enough. Not surprisingly, the actual with an electronic torque trans-
torque applied to the fastener could ducer. Because impact wrench-
vary by 30 percent to 50 percent. es apply torque in short bursts,
However, new technology measuring and controlling their
has improved the torque control torque electronically has been
capability of these tools. For nearly impossible.
example, Atlas Copco’s impact Stanley found a way around the
Impact wrenches are ideal for tightening large fasteners wrench has an adjustable problem by applying a technology
in heavy trucks, agricultural equipment, construction mechanism that shuts off the tool originally developed by Magna-
machinery and railcars. Photo courtesy Atlas Copco Tools
when a preset number of impacts, Lastic Devices Inc. (Chicago) for
and Assembly Systems
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22 ASSEMBLY / 1July 2009 www.assemblymag.com

Asb07094schunk.indd 6/15/09 2:09:22 PM
measuring torque produced by rotating The tool’s pin-clutch design For reprints of this article,
shafts in vibrating machinery, such as enhances the ability of the electronics please contact Cindy Williams
harvesters, helicopters and winches. to control torque. The clutch applies at williamsc@bnpmedia.com
The technology works like this: The torque in smaller increments than the or 610-436-4220 ext. 8516.
wrench’s output shaft is magnetized. traditional twin-hammer mechanism
When torque is applied to the shaft, it found in most impact wrenches. ASSEMBLY ONLINE
creates highly repeatable changes in the “It’s not the same level of control as For more information on power tools, visit www.
shaft’s magnetic field. Electromagnetic a continuous-drive DC electric tool,” assemblymag.com to read these articles:
coils surrounding the shaft detect concedes Versele. “But you can get Torque Trade-Offs.
those changes and send the signals a Cpk of 1.67 ±10 percent on a well- Don’t Shut Off the Air.
to an electronic controller. Software designed joint.” A Choosing the Optimum Fastening System.
translates the signals into meaningful
torque data that can be used for closed-
loop control of the fastening process.
An additional sensor can be added to
measure and control angle.
When a preset torque and angle
have been reached, the controller
automatically shuts off air to the tool,
says Doug Versele, global product
manager for industrial and automotive
power tools at Stanley. The controller
has 24-volt I/O for connecting to a PLC
and Ethernet ports for sending fastening
data to a shop-floor network. The
wrench is equipped with a headlight
to illuminate the workpiece. The light
turns green if the fastener has been
tightened correctly; it shines red if it
hasn’t.
The impact mechanism in Atlas Copco’s

LMS series of wrenches is tightly sealed to
prevent lubrication from being expelled during
operation. This minimizes maintenance and
increases the life of the tool. Photo courtesy
Atlas Copco Tools and Assembly Systems

ASB05094Techno.indd 1 4/20/09 3:20:02 PM
Special Report:
State of the Profession 2009
Ready
for the
Recovery
Assemblers are worried, but hours, which was a record low, accord-
ing to the U.S. Department of Labor
Positive Signs
Several recent reports by econo-
cautiously optimistic. (Washington, DC). Numerous com- mists indicate the latter. For instance,
panies announced layoffs in March, the National Association for Business
pushing the unemployment rate to 8.5 Economics (NABE, Washington, DC)
By Austin Weber percent, the highest level in 26 years. claims the recession will end soon.
Senior Editor Manufacturers in all industries have “While the overall tone remains soft,
slashed their budgets in recent months. In there are emerging signs that the recov-
T
he end is near. After endur- fact, 80 percent of assemblers claim that ery is stabilizing,” says Chris Varvares,
ing the most nerve-wracking budget cutbacks are affecting their plants, NABE president. “[However], the eco-
economic boom-to-bust period which is a 44 percent increase over last nomic recovery is likely to be con-
since the Great Depression, year. Another sign of the times is salary. siderably more moderate than those
assembly professionals finally Only 31 percent of survey respondents typically experienced following steep
see light at the end of the expect to receive a pay increase this year declines.
long, dark tunnel. While the automo- vs. 76 percent in 2008. “The key downside risks remain
tive and housing markets remain flat, Numerous individuals have experi- continued large job losses, no improve-
they are beginning to show signs of enced pay cuts, furloughs and elimi- ment in credit conditions and further
life. Confidence is slowly starting to nation of benefits. And, an even more sharp declines in home values,” adds
return to both Wall Street and Main sobering statistic is the fact that more Varvares, who also serves as president
Street. That’s good news for assembly than half (60 percent) of respondents of Macroeconomic Advisers LLC (St.
professionals, who are eager to start claim that their retirement plans have Louis). “These same forces are causing
ramping up their production lines. changed because of the economy. consumers to remain cautious. The good
The 2009 ASSEMBLY State of the Despite enduring those hardships, news is that economic growth [will]
Profession survey was conducted in assembly professionals remain rela- turn positive in the second half of this
early March, shortly after the contro- tively upbeat. Indeed 38 percent of year, with the pace of job losses narrow-
versial $787 billion economic stimulus respondents claim they are “highly ing over the remainder of the year and
plan was signed by President Barack satisfied” with their jobs, which is employment turning up in early 2010.”
Obama. However, the news at the time 1 percent higher than 2008. Perhaps Other experts, such as Robert
was bleak. New vehicle sales were those individuals are just happy to have Gordon, an economics professor at
down 37 percent in March. And, the a job, or maybe things are finally start- Northwestern University (Evanston,
average work week dropped to 33.2 ing to pick up. IL), agree with that assessment.

Ironically, he bases his opti- Labor Shortage Is Not a Big Concern earns $75,317. However,
mism on claims for unem- there are exceptions at both
ployment benefits. Gordon the high and low ends of
believes the peak in jobless the scale. For instance, 11
claims, which occurred in 42% percent of respondents take
April, typically takes place 41% home less than $50,000 per
during the bottom curve of a year, while 23 percent earn
recession. 36% more than $90,000.
34%
Another good indicator of But, some other statis-
economic health is corporate 26% tics are more sobering. For
profit. According to the U.S. 24% instance, only one-third (34
Department of Commerce’s percent) of respondents claim
Bureau of Economic Analysis they received a pay increase
(Washington, DC), corporate over the last 12 months. Most
profits from current produc- individuals were not that for-
tion increased $43 billion in tunate. Indeed, two-thirds
2004 2005 2006 2007 2008 2009
the first quarter of 2009, in (66 percent) of assemblers
sharp contrast to a decrease of $250 bil- historical standards, as far as consum- did not receive a raise.
lion in the fourth quarter of 2008. ers are concerned, the worst is now But, considering the state of the
The Institute for Supply Management behind us. economy, that’s no surprise. According
(ISM, Tempe, AZ) claims that the “After two months of significant to Hewitt Associates (Lincolnshire, IL),
U.S. economy grew in May for the improvements, the Consumer Confidence American workers are experiencing the
first time in seven months. “While Index is now at its highest level in nine lowest pay raises in 32 years as compa-
employment and inventories continue months,” claims Franco. “Current con- nies attempt to manage overhead costs.
to decline at a rapid rate . . . there are ditions have moderately improved, and “Many organizations are being nega-
signs of improvement,” says Norbert growth in the second quarter [was] less tively impacted by the economy,” says
Ore, ISM’s chairman. The machinery negative than in the first. Consumers’ Ken Abosch, North American practice
and plastics industries both reported short-term outlook [has] improved sig- leader for Hewitt’s compensation con-
growth in May. nificantly. Those expecting business con- sulting business.
Recent studies conducted by the ditions will improve over the next six “Short-term adjustments to reduce
Federal Reserve Bank of New York months increased to 23.1 percent from fixed costs are required to avoid pay
and the National Association of Home 15.7 percent.” freezes, layoffs, or in some cases, just
Builders (NAHB, Washington, DC) to survive,” Abosch points out. He says
also indicate that the economy is slow- Salary Statistics making across-the-board cuts to salary
ly improving. For example, the number The typical State of the Profession increases is one of the quickest and
of newly built single-family homes on survey respondent is 48 years old, has easiest ways for companies to lower
the market shrank to 297,000 units an average of 18 years experience and overall costs.
in April, thinning supplies to their
lowest level since May 2001. “This
continued reduction in the new-homes
inventory helps bring supply in line
with demand, which is an important
step toward the market’s recovery,”
explains David Crowe, NAHB’s chief
economist.
“Consumers are considerably less
pessimistic than they were earlier this
year, and expectations are that busi-
ness conditions, the labor market and
incomes will improve in the coming
months,” adds Lynn Franco, director
of the consumer research center at the
Conference Board Inc. (New York).
“While confidence is still weak by More assembly plants are initiating recycling programs. Photo courtesy IBM Corp.

How Industries Compare

residential, retail and office furnishings,
Industry Segment* Salary Work Week in addition to architectural millwork,
cabinets, mattresses, shelving and
Computer and electronic products $77,794 45.3 hours
window blinds.
Electrical equipment and appliances $79,570 45.3 hours Machinery manufacturing:
includes agricultural equipment, con-
Fabricated metal products $69,304 45.0 hours struction equipment, conveyors, food
processing machinery, lawn and gar-
Furniture and fixtures $78,592 44.9 hours den equipment, machine tools, office
machines, packaging machinery, pho-
Machinery manufacturing $72,539 43.8 hours tographic equipment, printing presses,
power tools, pumps and compressors,
Medical equipment, devices and instruments $74,802 46.0 hours refrigeration and heating equipment,
textile machinery, vending machines
Plastics and rubber products $71,618 46.1 hours
and welding equipment.
Transportation equipment $78,936 45.8 hours Medical equipment, devices
and instruments: includes medical
National average $75,317 45.1 hours diagnostic and monitoring equipment,
in addition to cannulas, catheters, diag-
*Based on North American Industry Classification System (NAICS)
nostic test kits, dialysis aids, filters,
inhalers, orthopedic implants, pumps,
Computer and electronic Electrical equipment and scalpels, stents, stethoscopes, surgi-
products: includes antennas, audio- appliances: includes batteries, cal kits, syringes, tubes, valves and
visual equipment, automatic teller flashlights, generators, household wheelchairs.
machines, clocks, computers and appliances, industrial controls, lamp Plastics and rubber products:
peripherals, connectors, digital cam- bulbs, lighting fixtures and equipment, includes belts, bottles, floor coverings,
eras, flat-panel displays, laboratory motors, switches and transformers. hoses, packaging materials, pipes and
instruments, loudspeakers, navigation- Fabricated metal products: fittings, plumbing fixtures and tires.
al instruments, printed circuit boards, includes ammunition, cans and Transportation equipment:
process control instruments, railroad containers, cutlery, doors, fences, includes automobiles and automotive
signaling equipment, satellites, semi- firearms, hand tools, hinges, ladders, components, aerospace equipment,
conductors, smoke detectors, stereos, locks, metal stampings, plumbing aircraft, boats, engines, motor homes,
telephone apparatus, televisions, test fixtures, prefabricated buildings, railroad locomotives and rolling stock,
and inspection equipment, transmit- springs, valves and windows. recreational vehicles, ships, trailers
ters, video recorders and watches. Furniture and fixtures: includes and trucks.
Less than one-third (31 percent) of 2008. Assemblers in the medical they expect a raise during the next 12
State of the Profession respondents device industry feel most confident months.
expect to receive a salary increase at about receiving an increase. Indeed, But, assembly professionals in the
their next review vs. 76 percent in 51 percent of those individuals say transportation equipment industry,
which include automakers and sup-
Staff Size Is Decreasing pliers, are less optimistic. Because
of the dramatic slowdown in the auto
2009 Increase 13% industry, only 24 percent believe they
2009 Decrease 67% will receive more compensation in the
near future.
2008 Increase 35%
A recent study conducted by Grant
2008 Decrease 33% Thornton LLP (Chicago) concurs with
ASSEMBLY’s findings. Jack Katz,
2007 Increase 37%
national managing partner of Grant
2007 Decrease 30% Thornton’s financial services practice,

claims that 58 percent of U.S. manu- Assembly professionals tend to be to region. Often, those fluctuations are
facturers will cut their operating costs loyal employees who stay with the determined by the local cost of liv-
by not giving out raises in 2009. In same company for long periods of ing. Traditionally, the West (Arizona,
addition, he says 48 percent of compa- time. In fact, 46 percent of respondents California, Colorado, Idaho, Montana,
nies will not hand out bonuses. have worked at the same firm for more Nevada, New Mexico, Oregon, Utah,
Less than half (44 percent) of than 10 years, while 14 percent have Washington and Wyoming), which is
ASSEMBLY’s respondents received a been with their present employer for home to only 13 percent of respon-
cash bonus during the last 12 months, less than two years. dents, boasts the highest salaries in
a 14 percent decrease from 2008. Most the State of the Profession survey.
of that extra compensation was tied Geography Determines Pay However, assemblers in the West also
to overall company and plant perfor- Assembly salaries vary from region work 0.5 hour more than the national
mance, in addition to meeting deadlines
for new projects and implementing
successful cost reduction programs.
More than one half (56 percent) of
assemblers who work for companies
A TRUSTED NAME.
that manufacture medical equipment,
devices and instruments claim they
received a cash bonus during the past
RIVETING
year. By comparison, only 33 percent
of assemblers in the plastics and rubber
NEW PRODUCTS.
products industry received bonuses.
Unfortunately, a large gender gap
still exists in the assembly profes-
sion, but it appears to be slowly nar-
rowing. The average salary of female
assemblers (4 percent of respondents)
is $64,791. Their compensation lags
behind male assemblers by $10,915
or 14 percent, which is an 11 percent
decrease from 2008.
More than one-half (58 percent)
of the women surveyed earn less than
$70,000, while 57 percent of the men
earn more than $70,000. One factor
that accounts for some of this dis-
crepancy is the fact that the women
respondents had an average of 14 years
experience in the assembly field, while
men averaged 19 years of experience.
In addition to gender and experi-
ence, several other factors determine
average pay rates, such as age, educa-
tion, location and industry. Industry
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average of 45.1 hours per week. used in pacemakers and implantable

The average salary in the West is cardioverter defibrillators.
$79,467, which is 5 percent more This summer, MFG Galileo
than the national average of $75,317. Composites Corp. (Sparks, NV), a lead-
Assemblers in the Northeast (Connecticut, ing manufacturer of radomes and reflec-
Maine, Maryland, Massachusetts, New tors, is opening a 40,000-square-foot
Hampshire, New Jersey, New York, plant in Opp, AL. In addition, the National
Pennsylvania, Rhode Island and Vermont) Alliance for Advanced Transportation
and the Midwest (Illinois, Indiana, Iowa, Batteries (Argonne, IL) recently chose
Kansas, Michigan, Minnesota, Missouri, Glendale, KY, as the site for a $600 mil-
Nebraska, North Dakota, Ohio, South lion lithium-ion battery plant.
Dakota and Wisconsin) also earn more Assemblers in the West are also
than the national average. the most confident about receiving a
Assembly professionals in the salary increase at their next review.
South (Alabama, Arkansas, Delaware, Indeed, 34 percent (vs. 74 percent in
Florida, Georgia, Kentucky, Louisiana, 2008) of respondents say they expect
Maryland, Mississippi, North Carolina, a raise. However, only 27 percent of
Oklahoma, South Carolina, Tennessee, assemblers in the Midwest, home of
Texas, Virginia and West Virginia), the beleaguered auto industry, believe
which is home to 20 percent of respon- they’ll receive a pay increase during
dents, earn 7 percent less than the the next 12 months.
national average. That may be one rea- Of course, money can’t buy hap-
son why many manufacturers continue piness. Assembly professionals in the
to flock to the region. West earn more than their peers in
For instance, Volkswagen AG other parts of the country, but they also
(Wolfsburg, Germany) is build- tend to be less satisfied with their jobs.
ing a $1 billion assembly plant Only 86 percent of respondents claim
in Chattanooga, TN, that’s sched- to be satisfied vs. 96 percent in the
uled to open in 2011. NCR Corp. South and 94 percent in the Northeast.
(Dayton, OH), a leading manu- One reason for that extra bit of
facturer of ATM machines, just happiness in the South may be due to
announced that it plans to build a the fact that more assemblers see their
state-of-the-art manufacturing plant companies committing resources to
in Duluth, GA. Earlier this year, St. assembly operations during the next
Jude Medical Inc. (St. Paul, MN) three years. Indeed, 63 percent of
opened a 60,000-square-foot plant in respondents are optimistic vs. 56 per-
Liberty, SC, to assemble electronics cent in the Midwest. In addition, 40
Geographic Salary Variables
Northeast
$78,000
Midwest
$75,489
West
$79,467
South
$70,097

percent of assemblers in the South claim Company Size Impacts Salary Size
that their company has increased staff
size during the past year, compared to $90,699
only 34 percent of respondents in the
$85,000
Midwest.
Overall, assemblers who claim to be
“highly satisfied” with their jobs earn $80,000
an average of $78,948, compared to
$78,240
$74,057 for people who claim they are
“moderately satisfied.” Not surprising- $75,000 $73,918
ly, individuals who are “not satisfied”
typically do not receive cash bonuses $73,894
and provide little or no input on bud- $70,000
geting new assembly equipment. $69,472
Size Does Matter $65,000

Salary and job satisfaction levels
in the assembly profession are usually
influenced by the size of a manufactur- Less than 100 100 to 249 500 to 999 1000 to 1,999 2,000 or more
er. For instance, assemblers who work Number of Employees
in companies with more than 2,000
employees tend to earn the highest However, bigger isn’t always better, smaller firms.
average salary: $90,699. On the other especially when it comes to compen- Indeed, 44 percent of people who
hand, small manufacturers with less sation. Assembly professionals who work in small companies (firms with
than 100 employees pay an average work in larger companies are generally fewer than 100 employees) claim they
salary of $69,472. less happier than those who work for are “highly satisfied” with their jobs
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Future Allocation to Assembly Processes parallels the national average, with a

salary of $74,802.
OEMs Less allocation Contract Assemblers Manufacturing engineers (44 percent
More allocation to assembly Less allocation
to assembly More allocation of respondents) rank slightly ahead of
21% to assembly to assembly
39% 33% design engineers (15 percent of respon-
38%
dents) when it comes to compensation.
They earn an average of $159 more
than their peers and they tend to work
slighter shorter work weeks. However,
design managers make quite a bit more
than manufacturing process managers:
Same/no Same/no
change
an average of 11 percent more.
change
40% 29% Age is another important factor that
often influences compensation. For
instance, manufacturing engineers who
vs. 31 percent of respondents who industrial controls, lighting fixtures, are under 50 years old earn more than
work in companies with more than motors, switches and transformers, design engineers of the same age.
1,000 employees. Assemblers who earn the highest salaries: $79,570. Assembly professionals who are
work for manufacturers with 500 to Their compensation is 5 percent above more than 60 years old typically earn
999 employees most closely match the the national average of $75,317. the highest salaries. For example, indi-
national “job satisfaction” average of Other industries that boast salaries viduals who are 60 or older earn 14
38 percent. above the national average include percent more than their peers who are
Assembly professionals in the transportation equipment (5 percent in their 30s and 33 percent more than
electrical equipment and appliance higher) and computer and electron- 20-year-olds. The average salary for
industry, which includes manufactur- ic products (3 percent higher). The assemblers in their 60s is $83,342,
ers of batteries, household appliances, medical device industry most closely compared to an average of $71,938 for
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ASB11084Ells.indd 1 10/6/08 1:17:17 PM
respondents in their 30s. designation earn an average salary 7 Job satisfaction can be defined many
Salaries also fluctuate dramatically percent higher than noncertified engi- different ways. But, here’s what a few
based on type and level of education. neers. Individuals with P.E.s (7 percent respondents had to say:
For instance, assembly professionals of respondents) earn an average of “Each day represents a new chal-
with just a bachelor’s degree (57 per- $83,372, while CMfgEs (5 percent of lenge, and the constantly changing
cent of respondents) earn an average of respondents) make $78,604. business environment requires always
$75,881. However, assemblers with mas- staying on your toes,” says a plant
ter’s degrees (16 percent of respondents) Happiness Counts manager in the medical device indus-
earn an average of $12,547 more than Most respondents claim to be satis- try who is satisfied with his job.
individuals who only have 4-year college fied with their jobs, but a closer look at “I am in a position where I am able
degrees (a 14 percent difference). the data reveals some differences. For to make decisions and changes with
One way to earn a higher salary is by example, manufacturing engineers tend minimal outside influences,” adds a
obtaining a master’s in business admin- to be happier than design engineers. manufacturing engineer in the electri-
istration (MBA). The ASSEMBLY sur- Indeed, 34 percent of manufacturing cal equipment and appliance industry.
vey discovered that MBAs (7 percent engineers claim to be “highly satisfied” “I work for a great company, with
of respondents) make an average of 19 vs. 28 percent of design engineers. good people and a supportive envi-
percent more than non-MBAs. In fact, The happiest assemblers work in the ronment for education and improve-
58 percent of MBA respondents earn fabricated metal products industry, where ment,” notes a manufacturing engi-
more than $80,000. However, MBAs 49 percent of respondents claim to be neer at a transportation equipment
typically work longer hours than other “highly satisfied” with their jobs. In con- manufacturer. “We make interesting
individuals. trast, only 24 percent of assemblers in the products and there are some chal-
Another way to guarantee a high- plastics and rubber products industry are lenging production processes that
er-than-average salary is to become “highly satisfied.” Assembly profession- are fun to ‘lean out.’”
certified. Assemblers who hold a certi- als who work for contract manufacturers “I have direct control over
fied manufacturing engineer (CMfgE) are 6 percent happier than their peers expenditures and policies that impact
or professional engineer (P.E.) who work for OEMs. operational performance,” says a design

asb06094dymax.indd 1 5/5/09 9:55:33 AM
State of the Profession
State of the2009
Profession 2009
Actions Taken Because of Economy

Layoff employees 86%
easy • accurate • automatic Reduce
59%
workweek hours
ALL NEW Mandatory pay cuts

Eliminate 401(k) 23%
30%
DSP Sensor contributions
The Ultimate in engineer in the computer and electronic satisfied with their jobs. “Upper man-
products industry. “Therefore, I am agement seems out of touch with actu-
Handheld Laser allowed to create my own strategies al product demands and part shortage
Profilers that facilitate achievement of company constraints,” laments a manufacturing
objectives.” engineer in the machinery manufactur-
“I work for a great small company ing industry.
and I enjoy what I do,” explains a man- “China is right on our heels,” gripes
ufacturing engineer in the fabricated a design engineer in the furniture and
metal products industry. “I wear many fixtures industry. “We need to get more
hats and that gives me great opportu- advanced, but we are not doing it
Run it in nity to use the skills that I have.” quickly enough.”
Standalone Mode “It is enormously gratifying to see
our equipment in use in operating rooms,
“The economic downturn, com-
bined with reduced resources and an
•No cable, no tether to
helping to make a positive difference for increased workload, leave me over-
an external device
sick patients,” says a design engineer at whelmed, underpaid and not appreci-
•Use as a data collector
a medical device company. ated,” adds a plant manager in the
or Go/No-Go Gage
However, some respondents are less plastics and rubber products industry.
•View and save data
•Integral battery -
4 hour run time
•Weighs 20 ounces with Survival Strategies Differ
battery
by Industry
Or Use it as a USB When the economy soured late last year, manufacturers reacted
Device With Your Laptop differently. More than three-fourths (77 percent) of the 2009 State of
the Profession survey respondents said they reduced inventory. Other
or Tablet PC popular strategies included tightening the supply chain (65 percent)
•Enhanced graphics and implementing improvement projects or holding kaizen events (60
and data analysis percent). Assemblers have also increased lean training (52 percent),
•Automatically save customer dialogue (49 percent), equipment maintenance (46 percent)
every scan and line rebalancing (41 percent).
•Run inspection Inventory reduction is more prevalent in the transportation equipment
routines industry (84 percent) and less critical in the computer and electronic
•Compare results from products industry (69 percent). Transportation equipment manufacturers
different algorithms also prefer line rebalancing (58 percent), while equipment maintenance is
on the same scan more common in the fabricated metal products industry (56 percent).
On the other hand, customer dialogue is more popular in the plastics
and rubber products industry (68 percent) than in the medical device
industry (37 percent). Plastics and rubber product manufacturers are also
more eager to conduct kaizen events (76 percent) than their peers in the
machinery manufacturing industry (55 percent).
Large companies are more willing to reduce inventory or invest in lean
training. For example, 66 percent of plants with 1,000 or more employees
www.origintech.com have engaged in training activity recently because of economic conditions.
256-461-1313 In contrast, only 45 percent of manufacturers with less than 100 employ-
ees have turned to lean lessons.

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neers take a back seat to design engi-
neers,” says a manufacturing engineer in
the electrical equipment and appliance
field. “Engineers in general are consid-
ered only one step above a technician.”
“My company suffers from poor ISO 9001:2000
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Widespread budget cutbacks asb06094ells.indd
having a huge impact on job satisfac-
are 1
Technifor Direct Part Marking 5/18/09 10:31:52 AM
tion. Unfortunately, it’s a problem that

affects assemblers who work for both
and Traceability
large and small manufacturers. For
instance, 67 percent of respondents at
small manufacturers (companies with
100 or less employees) claim that
budget cutbacks are affecting their job
vs. 86 percent of respondents at large
manufacturers (companies with 2,000
Micro-Percussion Scribing Laser Marking
or more employees).
Assemblers in the transportation
equipment industry (88 percent), which
includes automakers and auto part sup- Contact us for in-plant
pliers, are the most concerned about analysis and demos.
budget cutbacks. That’s not surprising,
since Chrysler and General Motors
recently declared bankruptcy. Even Tag Marking 2D Coding
automakers such as Honda and Toyota & Reading
have scaled back production.
Not surprisingly, respondents in the 800-394-9101
Technifor, Inc.
medical device industry (66 percent) are
Tel. 704-525-5230
less concerned about budget cutbacks. Fax. 704-525-5240
www.technifor.com
Assemblers in that field are much more e-mail: tfinc@usa.technifor.com UID Compliant
concerned about issues such as keeping

ASB06074Technifor.indd 1 5/3/07 10:59:44 AM
The Harsh Realities of a Slow Economy

There have been many casual- of their assembly operations. The most facturers have taken that route vs. 25
ties of the recent economic collapse. stability is on the West Coast, where percent of small firms.
Unfortunately, layoffs are often the only 60 percent of assemblers claim If the poor economy continues,
first way companies react to sluggish they work in plants that have experi- more manufacturers may be forced to
sales and lack of demand. When the enced headcount reductions. suspend their employer 401(k) match
economy turned south late last year Mandatory pay cuts have affected the to cut operating costs. According to
and early this year, more than three- medical device sector (41 percent) the Hewitt Associates (Lincolnshire, IL)
fourths (86 percent) of 2009 State most, while that action is less common in companies can save millions of dol-
of the Profession survey participants the electrical equipment and appliance lars by eliminating the practice for just
experienced the stress of layoffs. Other industry (23 percent). Reductions in one year.
cost-cutting activities included reduced hours are more common in the furniture “A typical large company can see
hours (59 percent), mandatory pay cuts and fixtures industry (88 percent), which savings of $25 million a year,” says
(30 percent) and elimination of 401(k) has been hard hit by the slump in hous- Pam Hess, Hewitt’s director of retire-
contributions (23 percent). ing and construction, and least common ment research. “The average midsized
Industries that have been hardest is the medical device field (41 percent). company can save more than $10 mil-
hit by layoffs include plastics and Large manufacturers are more likely lion, and the average small company
rubber (91 percent), computer and to mandate pay cuts. For instance, 40 can save nearly $2 million annually.
electronic products (90 percent) and percent of plants with 2,000 or more “Companies are making difficult
machinery manufacturing (88 percent). employees have cut wages within the decisions to keep their bottom line in
The medical device industry has been last year because of the economy. By the black, and the employer 401(k)
least affected, with only 77 percent of comparison, only 26 percent of manu- match is one of the costliest retire-
assemblers citing layoffs. facturers with less than 100 employment expenditures they sustain in a
Assembly professionals in the ees have slashed their payrolls. given year,” adds Hess. “Cutting this
Midwest have been the hardest hit, However, large companies are less benefit to reduce costs is a much less
with 73 percent of respondents likely to eliminate 401(k) contribu- drastic action than eliminating jobs or
reporting reductions in the overall size tions. Only 19 percent of large manu- reducing salaries.”
up with state-of-the-art technology and manufacturers (56 percent) and medi- with a weekly average of 46 hours. At
making new technology work. cal device manufacturers (53 percent). the other end of the spectrum, respon-
Because of the economy, many dents who work in the machinery man-
assemblers believe their plants will Less Time to Complain ufacturing industry put in an average of
be investing in less capital equipment Because of cutbacks, assembly 43.8 hours per week.
in the near future. When asked, “How professionals are spending less time However, assembly professionals
do you see your company committing on the plant floor these days. In fact, who put in longer hours tend to earn
resources toward improving assembly 73 percent of respondents currently higher salaries. For instance, individu-
operations during the next three years?” work more than 40 hours a week (vs. als who work an average of 46 to
21 percent said “less resources” vs. 13 88 percent in 2008). The national 50 hours a week earn an average of
percent in 2008. The two industries average is 45 hours, which is one $81,806. Individuals who typically
that are most bullish about committing hour less than in 2008. work less than 40 hours a week earn
resources to new production equipment Assemblers in the medical and plas- $68,238.
include plastics and rubber products tics industries work the longest days, Corporate managers claim to have
the longest work weeks: an aver-
Response to Economic Conditions age of 46.8 hours. By comparison,
design managers average 46.7 hours,
Reduce inventory 77% followed by manufacturing managers
Tighten supply chain 65% (45.7 hours), manufacturing engineers
(44.6 hours) and design engineers
Improvement projects/kaizen 60%
(44.1 hours). Unfortunately, the trend
Lean training 52% toward shorter weeks is expected to
Customer dialogue 49% continue during the next 12 months,
with 11 percent of assemblers claim-
Equipment maintenance 46%
ing that their average work week will
Rebalance assembly lines 41% decrease vs. 6 percent in 2008.

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Assemblers in the South and West
plan to work more than their peers in
other regions. For instance, 31 percent
of respondents in those parts of the
United States believe the hours they The Direct Alternative!
spend at work each week will increase
during the year ahead. On the other
hand, only 26 percent of assemblers in
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constraints will affect their ability
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months. Time constraints will also
have a bigger impact on assemblers
who work in large companies. asb07094weiss.indd
For 1 6/15/09 4:11:53 PM
instance, 64 percent of assembly

professionals who work for compa-
nies with 2,000 or more employees
will be affected by time constraints
vs. only 44 percent of respondents
in companies with less than 50
employees.
Time constraints will cause the
most stress on assemblers who work
in the transportation equipment indus-
try (57 percent) and the computer
and electronic products industry (55
percent), who are under intense pres-
sure to launch new products and meet
deadlines for projects.
However, for the first time in years,
a shortage of skilled labor will not
be a major constraint or barrier in
assembly plants. Only 26 percent of
respondents cited this as a challenge
vs. 42 percent in 2008. Concern over
finding assemblers is greatest in the
fabrication metal products industry (33
percent) and lowest in the medical
device industry (17 percent).

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Factors Contributing to Competitive Advantage
71%
69%
67%
59%
43%
39%
36%
36%
34%
20%
Green Movement Is Growing garbage is recycled, reused or con-

According to the State of the verted to energy. At GM’s landfill-free
Profession survey, green manufac- plants, more than 95 percent of waste
turing activity continues to increase is recycled or reused, while 4 percent
in various industries. In this year’s is converted to energy. Six GM plants
study, 57 percent of respondents claim in the United States use landfill-gas to
they are involved in green or sus- fire boilers or generate electricity.
tainability initiatives vs. 46 percent “A big part of being landfill-free is
in 2008. Actions include everything effective recycling,” claims Elizabeth
from plantwide recycling programs to Lowery, GM’s vice president for envi-
installing new energy-efficient lighting ronment, energy and safety policy.
systems. “Not only does this intensive focus
Green activity is most common in on recycling help the environment, it
the transportation equipment indus- helps the company’s bottom line.”
try, where 69 percent of assemblers For example, as a result of GM’s
work in plants that have implemented global recycling effort, scrap metal
environmental programs. For instance, sales generated more than $1 billion in
General Motors Corp. (GM, Detroit) revenue in 2008. In addition to steel,
is involved in an ambitious effort to the automaker recycled 17,000 tons of
reduce the environmental impact of wood, 20,000 tons of cardboard and
its worldwide manufacturing opera- 4,000 tons of plastic.
tions. One goal is to make 50 percent Assemblers in the electrical equip-
of the automaker’s plants landfill-free ment and appliances (61 percent)
by 2010. and computer and electronic prod-
More than 50 GM plants have ucts (55 percent) industries are also
already reached that goal, which actively engaged in green programs.
means that more than 800,000 tons of For instance, IBM Corp.’s facility in
waste is diverted from landfills each Poughkeepsie, NY, the recipient of
year. Facilities achieve landfill-free ASSEMBLY’s 2008 Assembly Plant
status when all production waste or of the Year award, is a good example

of a manufacturer that is committed to protecting the
environment.
The 315,000 square foot high-end server plant serves
as a pilot site for IBM’s new Green Sigma initiative,
which is based on Six Sigma. The goal of Green Sigma
is to apply principles of energy and water usage to lower
environmental impact, increase efficiency and reduce
costs.
Disassembly and remanufacturing play an important
role in the day-to-day operations of IBM’s Poughkeepsie
plant. During the last six years, the plant has reused more
than 11 million parts. More than 1,450 high-end systems
have been recovered, refurbished and reused, while more
than 25,000 metric tons of metal have been recycled.
Large manufacturers (companies with 2,000 or more
employees) are more likely to be involved with green
initiatives. For example, 64 percent of assemblers in that
category claim they have implemented sustainability pro-
grams at their plant during the last 12 months, compared
to only 39 percent of small manufacturers (companies
with fewer than 50 employees).
Survey Methodology
ASSEMBLY magazine would like to thank all the
respondents who participated in its 14th annual State of
the Profession survey. The survey was conducted online
in March 2009 by Clear Seas Research
(Troy, MI). All readers with e-mail
addresses were contacted electroni- ASB09064Qualbear.indd 1 8/14/06 3:47:45 PM
cally and encouraged to click a special

hot link to the online questionnaire.
The charts and tables in this report
highlight the major data gleaned from
the survey responses. On some of the
questions, the response rate does not
equal 100 percent due to rounding or
surveys that contained one or more
unanswered questions. In cases where
multiple responses were allowed, the Ergonomic Workplaces and Assembly Lines
total may exceed 100 percent.
Conductix-Wampfler has one critical mission:
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distribution and tabulation. For more Systems include the right mix of tool transporters,
information on this study, please con- tool balancers, and overhead electric/air
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ASSEMBLY Adhesive Bonding
Adhesives for
Trailer Assembly
Structural adhesives help
M
anufacturers of specialty fasteners were used to provide structural
vehicles, such as trailers, stability.
assemblers of trucks, trailers, truck bodies, buses and
construction machinery,
Some adhesive applications on our
trailer have already been tried and tested
buses and other specialty are increasingly using in the field. However, we also tried
adhesives and sealants to many new applications for adhesives
vehicles reduce costs, boost assemble frames, panels, booms and cabs and sealants. The end result is a tougher,
made of metal, plastic and composites. more reliable, better-looking trailer that
throughput and improve By building these components with cost less to build than a conventional
adhesives and sealants instead of welds, model.
aesthetics. threaded fasteners or rivets, engineers
Step by Step
Bonding bed to frame. In traditional
trailer construction, the floor is attached
to the frame using mechanical fasteners,
We constructed a
work trailer almost
exclusively using
adhesives and
sealants.
a time-intensive process that leaves the
trailer susceptible to water damage.
In our project, we bonded the wood
Henkel engineers assembled this trailer almost can reduce assembly costs, increase floor to the frame using Loctite 5570,
entirely with adhesives and sealants. throughput, distribute stress more an elastic adhesive and sealant that
uniformly and improve aesthetics. distributes the load evenly over the entire
To prove the efficiency, durability and frame and prevents water from leaking
cost-effectiveness of adhesive assembly, in through the floor panels. Only four
we acquired a trailer frame—7 feet wide screws per panel were required to install
and 10 feet long—and constructed a the entire floor. All totaled, we installed
work trailer almost exclusively using the floor in just 10 percent of the time
By Brian Noonan adhesives and sealants. The few fasteners that would have been necessary had we
Application Engineer that did make it into the trailer were used fasteners alone.
Henkel Corp. used to temporarily hold components Loctite 5570 is a one-part adhesive
Rocky Hill, CT in place while the adhesives cured. No based on a modified silane polymer.
The adhesive cures by reacting with
atmospheric moisture. Skin formation
and curing times depend on humidity,
temperature and joint depth. Under
normal conditions, the adhesive
develops functional strength in 24 hours
and fully cures in seven days.
This odorless, noncorrosive adhesive
does not contain solvents, isocyanates,
silicones or polyvinylchloride. Besides
wood, it adheres to stainless steel,
galvanized steel, aluminum, glass,
fiberglass and plastics. It is compatible
with most paint formulations. Resistant
to ultraviolet radiation, the adhesive can
be used for both interior and exterior
applications.
Bonding skins to frame. The sheet-
By bonding the skins to the frame with adhesive, 90 percent fewer fasteners were needed for
metal skin covering the sides of a trailer assembly, resulting in a better looking, stronger, more leak-resistant trailer. The same material was
are usually riveted or bolted onto the used to bond the door and roof skins.
frame.
Instead, we used two fast-fixturing polyurethane or silicone caulks seal Loctite 5510 is a one-part adhesive
structural acrylics: Loctite H4500 and gaps and prevent water penetration. based on a modified silane polymer.
H8600. During the cure process, we These sealants work well, but they will Free of isocyanates, solvents and
used screws to fixture the skin in place. yellow over time and do not last long in silicones, this low-odor, highly flexible
By bonding the skins to the frame with the harsh environment of the road. sealant resists vibration, movement and
adhesive, 90 percent fewer fasteners On our trailer, we used Loctite 5510 impact. Because it is impervious to UV
were needed for assembly, resulting in to seal gaps in the frame and all the light, the sealant will not degrade or
a better looking, stronger, more leak- skins, including the door and roof. Like crack over time. It fixtures quickly and
resistant trailer. This same process the adhesive we used to bond the floor, can be color-matched to the skins for
was used to bond the door and roof seamless assembly.
skins. The adhesive cures by reacting
Loctite H4500 is a highly with atmospheric moisture. It
thixotropic, two-part methacrylate develops functional strength in 24
adhesive for bonding metals, such as hours and fully cures in seven days,
steel, stainless steel and aluminum. but these times can be shortened by
It also bonds epoxy-coated metal, increasing exposure to moisture.
sheet-molding compound and many Bonding and sealing panel
plastics. The adhesive bonds to trim. The panel trim located around
metals without a primer. It contains the trailer’s frame was bonded using
a corrosion-inhibiting additive to Loctite H4500 and 5570. Panel trim
ensure long-term bond durability is normally riveted in place, then
even when exposed to moisture. sealed with polyurethane or silicone
Mixed at a ratio of 10-to-1, the caulks. The adhesives in our project
adhesive reaches fixture strength in simultaneously bond and seal trim
15 to 20 minutes at 70 F. materials, even in critical areas such
Loctite H8600 is two-part as wheel wells. While fasteners were
methacrylate for structural bonding still needed to help secure the panel
of galvanized steel. Mixed at a ratio trim, the use of adhesive reduced the
of 2-to-1, it reaches fixture strength number of fasteners by 90 percent
in 55 minutes at 72 F. This toughened and shortened assembly time by 40
adhesive has a high peel strength. A Usually, the trailer floor is attached to the frame using percent.
thick material, it can be applied to mechanical fasteners. Henkel engineers bonded the Bonding diamond plate and
wooden floor panels to the frame using a one-part
vertical surfaces without sagging. modified silane polymer adhesive. The engineers installed nose to skins. On a traditional
Seam sealing the frame the floor in just 10 percent of the time that would have trailer, the diamond plate is riveted
and skins. On standard trailers, been necessary had they used fasteners. onto the trailer skin, while the nose
Adhesive Bonding
On a traditional trailer, diamond plate is riveted onto the skin, Ordinarily, this galvanized steel bracket would be secured to the trailer wall
then sealed with caulk. Henkel engineers bonded the plate using a with more than 200 screws. Instead, it’s bonded in place with a structural
methacrylate adhesive, eliminating mechanical fasteners altogether. The methacrylate adhesive. Assembly time was cut by 70 percent, and fastener
adhesive unitized the assembly and avoided the possibility of rattling. count was reduced by 90 percent.
is bolted or riveted in place, then sealed For the nose assembly, we used the In the future, the nose assembly could
with caulk. On our trailer, the diamond same structural adhesive to bond and seal be redesigned to eliminate predrilled
plate was bonded with Loctite H4500, the nose to the skins, eliminating rivets. holes, thereby eliminating the need for
eliminating mechanical fasteners Because the nose assembly on our trailer fasteners.
altogether. The adhesive unitized the came with predrilled holes, screws had Bonding internal brackets. Most
assembly, eliminating any potential for to be inserted to prevent leakage. Still, trailer interiors have galvanized
rattling and producing a higher quality bonding reduced assembly time by 20 steel brackets for tying down cargo.
appearance. percent and fastener count by 30 percent. Ordinarily, we would have secured the
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bracket plate to the trailer walls using exterior of the trailer is decorated with
two screws per frame member. The graphics that were applied without
bracket itself would have been secured concern for the placement of metal
to the plate using 200 screws. fasteners. As of January 2009, the trailer
Instead, we used Loctite H4500 to has logged 7,000 miles and experienced
bond both the plate and the bracket. As no problems with structural integrity or
a result, we needed only one screw per leakage. In early February, the trailer
frame member to fixture the bracket started a tour of manufacturing locations
plate, and we needed just 20 screws to along the East Coast.
install the bracket. Assembly time was 70 For videos of each step of this
percent faster using adhesives, and stress assembly project, visit www.
is distributed evenly along the length gluemytrailer.com. A
of the bracket, making it more durable.
Adhesive bonding reduced fastener use For reprints of this article,
for this application by 90 percent. please contact Cindy Williams
Threadlockers for miscellaneous at williamsc@bnpmedia.com
hardware. For the limited number of The sheet-metal panels of this trailer or 610-436-4220 ext. 8516.
threaded fasteners on our trailer, we were bonded to the frame with a two-part
applied Loctite 2033 threadlocker methacrylate adhesive. The material has a
to prevent vibrational loosening and high peel strength and excellent resistance to ASSEMBLY ONLINE
ultraviolet radiation.
seizing. This medium-strength gel For more information on adhesive bonding,
adhesive locks and seals threaded joints The Results visit www.assemblymag.com to read these
ranging from 0.25 to 1 inch in diameter. The trailer was completed in April articles:
It cures in the absence of air between 2008. Since then, it’s been on the road, Adhesives & Automobiles.
close-fitting metal surfaces. It resists hauling a motorcycle and an all-terrain Adhesives for Structural Metal Bonding.
most chemicals, liquids and gases. vehicle throughout the country. The AIA: School Bus Learns Adhesive Lesson.
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Sovella Inc. tooling with the Tau and Theta controller
800-437-6772 provides full transducer control at value
infousa@sovella.com price levels from .5 to 200Nm in all
www.sovella.us configurations. EC tool packages offer
a scalable plant interface while not
compromising joint quality or production
performance. Contact Vito Laudati
for details
For More Information Contact Michael
Poth at mpoth@stanleyworks.com, visit
Phone: 610-694-4018
www.stanleyassembly.com, or phone Fax: 248-283-6618
440-461-5500 laudativ@bnpmedia.com
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Advertising call Vito Laudati:
630-694-4018
CASE STUDY Advertisement Advertisement
Tool Changers
Marson tool salvages Providing Needed
800,000 rivets. Flexibility
T
o compete in a formidable and uncertain market,
many automakers are adopting flexible manufac-
turing into their strategy to cut costs and increase
flexibility and quality. This flexible manufacturing pro-
A
customer of Alcoa Fastening Systems working with cess utilizes robots and tool changers in manufacturing
all aluminum 3/16” diameter open-end blind rivets multiple cars on one assembly line. Traditionally, most
reported that the mandrel was breaking 1/2” up the assembly plants are limited by their ability to produce
mandrel shaft. This left approximately 1” of the mandrel only one car model. When demand for the model being
exposed above the eyelet body flange, resulting in a 30% produced drops, the plant works at less capacity. And
installation failure rate. when the plant is re-tooled for a new model, much of the
Following Alcoa’s Q-C lab inspection process, an costly equipment is scrapped.
on-site inspection was scheduled at the customer’s Flexible manufacturing enables assembly plants to
assembly plant. After several more assemblies were build a different model car automatically by switching end-
completed with observed failures, visual inspection of effector tooling. This approach allows multiple models
the spent mandrels revealed the issue: the jaw bite was to be built by one plant, making the plant much more
less than 1/2” down from the mandrel point, indicating responsive to demand. In addition, a new flexible plant
that the riveting tool being used was not fully engaging re-fit only costs a fraction of a traditional plant re-fit.
the mandrel. This was causing the tool jaws to break the Chrysler is one of many companies that have
mandrel prematurely above the rivet head. Commonly adopted this flexible manufacturing process. As stated
referred to as Mandrel pull through (spiking)…yet all in IndustryWeek “We wanted to do changeovers in
rivet and application dimensions were with in spec. hours or days versus weeks -- not only to save money
After agreeing to try the Marson MP-3V air-driven but to rapidly gain market share when a product is
riveting tool, the customer completed 4 additional hot,” said Frank Ewasyshyn, Executive Vice President –
assemblies with no failures whatsoever. Manufacturing, Chrysler.
Subsequently, the customer has been using the Marson ATI’s engineering staff, the largest of its kind for a
MP-3V installation tool with no reported failures to date. robotic tooling company, has created many solutions to
The MP-3V was able to salvage 800,000 rivets, and resolve the engineering obstacles associated with this
ultimately, realize a significant time and cost savings to type of state-of-the-art manufacturing environment. Visit
the customer. www.ati-ia.com for more information on ATI’s end-effector
products and to see more information on this topic.
Alcoa Fastening Systems
Ron Chike ATI Industrial Automation
AFS-IDG Industrial Sales Manager 1031 Goodworth Drive
Ron.Chike@alcoa.com Apex, NC 27539
Office: 800-826-2884 Phone: 919-772-0115
Visit us at www.AFS-IDG.com Fax: 919-772-8259
Email: info@ati-ia.com
Web site: www.ati-ia.com

Advertisement Advertisement
CASE STUDY
Screwdriving System UV/VIS Adhesive
Saves Time and Ruggedized DC Motor
Money
C
ell phone towers are a
nearly ubiquitous fea-
ture of every city, town
and roadway in America.
These towers send and
receive signals to and from
your cell phone. The tow-
ers are equipped with filter
boxes that filter the high-
frequency range to generate
a narrow-band signal for the
A
data stream. The clarity of manufacturer involved in the appliance/power tool
each filter is adjusted by one markets needed a way to ruggedize their line of DC
or more setscrews, or thread- motors to make them more robust, reduce the number
ed pins, which are mechani- of field failures and replacement units, and increase the
cally positioned in each filter consumer’s confidence in the quality of the tools they
chamber to an axial depth. A counter-nut does the exact were using.
positioning and mechanically locks the setscrew. The DC motors utilized a rotating commutator that
When the nut counters the setscrew, it is possible for spun inside magnets at high speed. If the copper wire
the adjustment to shift on its own because of a thread- were to come loose from the armature mount on the
backlash. To avoid this effect and eliminate repeated commutator, this would change the center of gravity
adjustments, manufacturers of filter boxes use custom- of the spinning shaft, causing a wobble, which would
made setscrews, which are very expensive and still do not degrade the efficiency of the motor and damage it.
solve this thread-backlash problem. DYMAX recommended Multi-Cure 6-602-GEL
DEPRAG has developed a new screwdriving adhesive because of its multiple-cure mechanism, which
system specifically for manufacturers of mobile phone enabled it to cure with UV/VIS light, or heat, or in
technology. This system dramatically reduces cycle combination with an activator. This allowed the vendor
time when installing and adjusting the setscrews. It also to unitize the armature wires then thermal bake any resin
saves these manufacturers money by enabling them deep in the commutator windings that did not see light.
to use standardized hardware instead of custom-made They also used a DYMAX high-intensity light source that
setscrews. emitted a broad spectrum of UV/VIS light at intensities up
The system consists of a screwdriving head that to 2,500 mW/cm2, which was necessary for the depth-of-
accepts both the setscrew and the nut (see picture). Once cure and tack-free surfaces dictated by the application.
both fasteners are supplied to the screwdriving head, The process involved applying 6-602-GEL (with a
the setscrew is driven through the nut into the filter box. nominal viscosity of 25,000 cP) with an air/pressure
Thereafter, the nut is countered, without letting go of the dispensing system and needle tip applicator while the
setscrew, and its position is therefore positively locked. rotor was spinning, so the adhesive spread out evenly over
the wires, and then curing it with a UV/VIS lightguide for
Lori Logan 5-10 seconds. DYMAX 6-602-GEL cured in seconds and
Marketing Manager provided exceptional adhesion to the substrates as well as
DEPRAG Inc. impact and shock resistance.
640 Hembry Street
Lewisville, TX 75057 DYMAX® Corporation
(800) 433-7724 Toll-Free 318 Industrial Lane
(972) 221-8731 Phone Torrington, CT 06790
(972) 221-8163 Fax Toll Free: 1-877-DYMAX-UV (877-396-2988)
l.logan@depragusa.com info@dymax.com
www.depragusa.com www.dymax.com

EFD Dispensers Cut

Rotary Dial System Assembly Time 83%
S
witching from toothpicks to EFD dispensers helped
an electronics manufacturer cut use of an expensive
silver-filled epoxy by 50% and reduced assembly
time from 30 minutes to 5 minutes per part.
The company builds membrane switches used in
touch-pad applications. Because soldering’s intense
A
rotary dial system built recently by EDGEWATER localized heat could damage the flexible circuits inside
AUTOMATION (St. Joseph, MI) was purchased by the switches, the company uses silver-filled conductive
a manufacturer who needed a machine to assemble an epoxy to attach components.
automotive switch with seven variants. Previously, they Operators used toothpicks to spread the expensive
were using three individual robots, each robot taking 43 adhesive on small contacts on the flex circuits, but the
seconds to complete a switch. company president knew there had to be a better way.
The manufacturer turned to EDGEWATER Seeking a more accurate and efficient application method,
AUTOMATION to help solve this problem. he contacted EFD for information on their automatic
EDGEWATER came up with the eight station Rotary dispensing equipment, which uses a precisely timed air
Indexing Dial machine for programmable, point to point pulse to apply epoxies, adhesives, solder pastes and other
soldering of electrical switches to circuit boards. This assembly fluids in accurate, consistent amounts.
machine not only saved the customer time (the dial index With time-pressure dispensers, shot size is determined
machine is twice as fast as the three robots combined) and by a combination of air pressure, dispense time, and
money, but also saved them half their floor space. tip size. With setup completed, tapping the foot pedal
Because of the number of current and future model produces an identical deposit every time.
variants to be assembled on this machine, a high degree The company now has two EFD dispensers in daily
of flexibility and programmability was required. The end operation. The ability to apply epoxy quickly and
user states that their expectations were exceeded with the accurately and eliminate waste has lowered their adhesive
quality and the low PPM reject rate. And at the end of the costs by 50% and dramatically reduced assembly time.
day, the customer is pleased with minimal maintenance “Besides being expensive,” the president says, “the
requirements. epoxy we use has a very short pot life, so we have to get
This machine is simple, cost effective, precise, it on the contacts quickly. That’s where the dispensers
reliable and durable. For more information please contact really shine -- we went from 30 minutes to 5 minutes per
Edgewater Automation at 269-983-1300 or visit www. assembly, for an 83% increase in productivity.”
edgewaterautomation.com
Edgewater automation
481 Renaissance Drive
St. Joseph, MI 49085 EFD, Inc.
www.edgewaterautomation.com 40 Catamore Boulevard
269 983 1300 East Providence, RI 02914
Sales@EdgewaterAutomation.com 800.556.3484
401.431.7000
www.efd-inc.com/pr/asm-0709
info@efd-inc.com

CASE STUDY
Micro-Dot Gloves
Resolve Parts
Ellsworth Develops Handling Problems
“Cold Solder” Process
A
prominent automotive parts manufacturer that pow-
der coats parts for a hard, tougher finish needed bet-
ter gloves that provided day-long comfort, good grip
with high dexterity; eliminated deposit of body oils and
C
onnecting wires to flexible circuits can be a chal- lint on parts; and offer cost savings.
lenge. The high temperatures used in conventional The manufacturer tried various gloves for this
solder methods can damage substrate materials. Sol- new production line but workers found these gloves
der alternatives, silver-filled conductive epoxies, cure in uncomfortable to wear for long-shift work; increased
hours versus the much shorter assembly times provided hand fatigue and perspiration; or left lint on parts. Other
by solder techniques. Ellsworth Adhesives recently less expensive gloves also wore out quickly since workers
worked with a customer bonding wires to silver coated had to load 25,000 parts per day onto the production
PET. The customer needed a fast assembly method that conveyor hangers.
would not damage flexible circuit materials, but would The manufacturer turned to GO Gloves™ (Gloves-
provide high-durability connections and maximum con- Online, Inc.) for a solution since they were experienced
ductivity. glove specialists and handled a broad range of gloves
The solution involved using a UV cure urethane in for industrial applications. Once GO Gloves identified
combination with a silver-filled epoxy. Step one of the the production requirements and problems together with
process was to connect the wire to the silver circuit and worker’s concerns, they offered 3 coated glove options
apply the silver-filled epoxy over the connection. Step based on performance, comfort, and price.
two was to dispense a small drop of UV encapsulant over After weeks of testing the finished parts and reviewing
the epoxy/wire/substrate connection. While holding the worker evaluations, the manufacturer selected the All-
connection together, the assembly was then exposed Day® Micro-Dot Gloves since this model addressed each
to UV light. The rapid UV cure fixtured the assembly production problem and increased worker acceptance.
together holding the wire and flex circuit together with The solutions that the Micro-Dot Gloves provided
the filled epoxy connection. With the connection in were thinness, close fit, dust and lint free, great tactile and
place, the epoxy was then cured using a prescribed grip properties, breathablity, and worker comfort. Besides
cure schedule. Ellsworth was able to provide the epoxy being very cost effective, the manufacturer only had to
in two forms, premixed and frozen in syringes and in stock 2 sizes; one universal stretch size and one extra small
two component flexible packaging for transfer to one size for women with small hands since more sizes would
component syringes. have been required with conventional coated gloves.
GO Gloves
Ellsworth Adhesives Gloves-Online, Inc.
W129N10825 Washington Dr. 261 Towerview Court
Germantown, WI 53022 Cary. NC 27513
(Ph) 800-888-0698 919-468-4244
(Fax) 262-253-8619 Fax 919-468-4245
info@ellsworth.com www.industrial.gloves-online.com
www.ellsworth.com sales@gloves-online.com

Multiple
Lista Workstations Measurements -
Aid Digital Monitoring One LaserGauge®
Products
D
igital Monitoring Products is a leader in network
solutions for fast, cost-effective, centralized security
monitoring in applications of every size. The com-
pany was at the forefront of digital communications in
the security industry, and today continues to set standards
A
with its networked intrusion, fire and access control n automotive manufacturer was using the Laser-
products. Gauge® system to measure gap and flush on exterior
DMP’s manual assembly is used to handle insertion of fits as a part of its final-line inspections. A potential
odd-form components that cannot be machine- inserted. out-of-spec condition that involved a seal protruding out
For over five years, Arlink® 8000 workstations from of a closure gap was frequently noted by inspectors. The
Lista International Corp. served DMP well as the central specs allowed the seal to protrude to a specified height
element in the company’s manual product assembly. relative to the panels, but the inspectors had no reliable
Lista is a world leader in modular storage and workspace means of measuring the seal.
systems. Since the profile of the seal and the surfaces of the
Problems arose for David Peebles, DMP’s VP of adjacent panels could all be seen in the scans captured
Manufacturing on assembly lines. Peebles needed to by the LaserGauge®, the inspectors contacted Origin to
incorporate a progressive assembly system to address find out if the height of the seal could be measured at the
this, optimize efficiencies and prepare the assembly same time as the gap and flush.
department for growth and expansion. Fortunately, Arlink Because LaserGauge ® measurements are made
8000 workstations are accommodating. in software, it was a simple matter of modifying the
The Arlink 8000 modular workstations are designed algorithm to identify the seal’s surface and to determine
to accommodate changing or future needs. Configured the maximum height of the seal relative to the adjacent
in a variety of heights and lengths, they feature a unique panels. Using sample scans collected by the inspectors,
“starter and adder” system with optional back-to-back the algorithm was modified and provided to the plant for
configurations that enables unlimited layouts to adapt immediate implementation. From that point forward, the
to any space or support any process requirements. The inspectors were able to base their findings on accurate
workstation’s Definite Positioning System® makes and repeatable measurements.
relocating or adjusting worksurfaces, storage, shelving, One LaserGauge® system can be used to perform a
lights, power beams, footrests, etc. fast, easy and safe. range of inspections:
“Lista’s Arlink 8000 is a great value – an easy-to- 䡲 Corner Radius and Flange Length on sheet metal parts
assemble solution that’s high quality as well as cost- 䡲 Gap and Flush on BIW and all color surfaces
effective. Lista’s salespeople and design team have 䡲 Height of seal between assembled panels
provided excellent support. We’re looking at adding 䡲 Angle and Eruptions on spot welds
three additional new lines, and Lista workstations are 䡲 Undercut, Concavity and Convexity on welds
top of mind.”
Lista International Corporation

106 Lowland Street, Holliston, MA 01746
TEL 1-800-722-3020
FAX 508-626-0353 Origin Technologies Corporation
EMAIL sales@listaintl.com. 256-461-1313
Visit Lista’s web site at www.listaintl.com. www.origintech.com

CASE STUDY
Steering Knuckle
Bushing Press
APPLICATION:
Assembly of bushing into the right and left angular
steering knuckles used in transportation industry.
PROBLEM:
A new design steering knuckle using conventional,
non-controlled hydraulics assembly presses was creating
10% to 12% rejections during the assembly process.
A total tolerance of +-0.5mm is required on the

position of the bushing relative to a phantom datum point
on the casting. This tolerance or less must be held over
millions of parts, despite the fact the casting tolerance,
S
with phantom tolerance, was three times the finished ankyo America, Inc. was chosen by major machine
assembly tolerance. builder to provide high speed indexer with accuracies
that needed to be very tight for injection molded parts
Using closed-loop feedback from an external position on US auto maker door fittings. The tolerances needed to
transducer built into the fixture/tooling, the sensor be held at +/- 0.002” at a 30” radius. The machine builder,
communicates to an Electrical Mechanical Assembly Pro-Systems, located in Indiana has had a longstanding
Press (EMAP) which measures the assembly as it is relationship with their customer and knew that they could
being made and compensates in real time, for variations not afford to go with any other cam index company. The
in the individual parts. The bushing position is now held repeatability required of this particular application could
to better than +- 0.1mm. not be negotiated. The Alpha series indexer provided by
Sankyo America, Inc. was ran and tested at +/- 0.0016 at
SUMMARY: the 30” radius.
The closed-loop EMAP system functions as both
a controlled Electric assembly press and gauge. The Sankyo America, Inc.
system has on board force monitoring and external “The Global Standard in Cam Indexing”
sensing capability, standard. This allows the systems 937.498.4901
to measure, calculate, and offset for deflection and www.sankyoamerica.com
variance in part tolerance, while it is making the part to 10655 State Route 47
tolerance. Micron wear of tooling and fixture, over time, PO Box 4338
are detected and compensated as part of finished part Sidney, Ohio 45365
tolerance to provide greater part quality and equipment sales@sankyoamerica.com
up time. Assembly rejects on the steering knuckle
bushing press are now less than .001%. Systems also
includes force vs. position signature visualization HMI
with alarms to ensure the press fit, and stores information
for recall and later analysis.
Promess Inc.
11429 Grand River Road
Brighton, MI 48116
810-229-9334
promess@promessinc.com
www.promessinc.com

Effective Heat ServoPress Station

Assembles and
Management with
Marks Transmission
Casting Materials Component
D
uring operation
many automo-
tive electronic
devices produce heat.
Such heat must be
effectively dissipated
to prevent the device
from overheating.
Excellent thermo conductivity can be achieved already
during manufacture by using especially composed casting SCHMIDT® ServoPress Model 460 and Transmission
resins with the appropriate heat dissipating properties. Component Assembly
A
Problem: Overheating well-known manufacturer of automotive products
Managing the heat generated by automotive electronic worked with SCHMIDT® Technology, a leading
components presents one of the major challenges when manufacturer of precision assembly presses, to devel-
choosing production materials. If the heat produced op a more efficient and cost-effective way to assemble a
by power losses is not properly dissipated, a device is truck transmission component.
likely to overheat. For example, a simple mechanical The assembly process consists of pressing a
installation creates an air gap, which insulates the part countershaft with integral helical gear onto a helical gear.
that is generating the heat. As a result, heat cannot be Once assembled, alignment between the lower and upper
properly dissipated. gear must be within +/- 0.006” with a Cpk of 1.67.
Previously, the manufacturer used a hydraulic press to
Solution: Flush Contact with the Cooling Ambient Air perform the pressing operation. Although the operation
Successful cooling can only be guaranteed if the heat- utilized keyways in the tooling, a secondary gauging/
conducting elements and the cooling ambient air show testing operation was necessary to verify gear alignment.
optimum surface contact. In other words: flush thermal Another secondary operation painted a transmission
contact with reliable electrical insulation. In the electronics timing mark on each gear.
industry, an increasingly popular trend is to use heat- To significantly improve these production operations,
conducting resins. If care is taken to dispense the casting SCHMIDT Technology designed and built a completely
material bubble-free a perfect surface contact is established integrated assembly station featuring the SCHMIDT®
simultaneously. Therefore, with the correct resin and ServoPress Model 460 (maximum force of 33,000 lbs.)
dispensing system, managing heat conductivity becomes a and PressControl 4000. The PressControl 4000 provides
simple, inexpensive and extremely flexible manufacturing fully integrated monitoring for quality and is capable of
step. Scheugenpflug systems have proven their abilities interfacing with and controlling up to six ServoPresses or
during their use in production over many years. other CNC-operated axes.
Once initiated, the ServoPress controls the ram until it
Customer Benefits: lightly contacts the part, realigns the parts if necessary, and
This method may well be the most profitable in the presses them together. PressControl 4000 software verifies
industry, because it is saving costs in two major areas of the interference fit while statistically tracking the results.
manufacturing. First, a single casting material can handle The PressControl 4000 then activates a painting device
substrates of different shapes. Second, casting resins are to mark one gear and a dot peen marker to permanently
less expensive than other heat-conducting connectors. mark the other gear. Sensors verify part presence and
tooling position. And finally, the SCHMIDT® ServoPress
Scheugenpflug, Inc. System performs and controls all operations during one
2125 Barrett Park Drive NW, press cycle while simultaneously monitoring for quality.
Suite 104 SCHMIDT Technology Corporation
Kennesaw, Georgia 30144, USA Cranberry Corporate Center
770 218 0835 280 Executive Drive
sales.usa@scheugenpflug-usa.com Cranberry Twp., PA 16066-6415
www.scheugenpflug-usa.com 724-772-4600 • Fax 724-772-4688

CASE STUDY
Increased Throughput
& Precision Quality
Assurance for Automated
Production Lines
C
hallenge: A major Japanese automotive component
supplier required highly precise, advanced techniques
T
ransfer Tool Products started working with SCHUNK, to test automotive oxygen sensors, an integral part of
a world leader in Automation, Workholding and automotive emissions systems. The nature of the sensors
Toolholding Technology, to reduce the cycle time makes them extremely difficult to test, as the characteris-
within the manufacturing process of stamped air bag tics of the device change when power is applied to them.
components. Utilizing SCHUNK’s HSB gantry axis In addition, production rates could not be slowed, so the
along with 6 assemblies composed of LM linear units, testing process would have to be as fast as possible.
SRU rotary units and PZN-plus grippers, Transfer Tool Solution: Sciemetric’s Model 1508 hardware was
Products was able to achieve a 500 millisecond cycle loaded with sigPOD™ PSV software, which enabled
time. This cycle time reduction allowed Transfer Tool synchronous testing of 4 units to allow greater throughput
Products to reduce the manufacturing cost of this stamped at the scale necessary on this major manufacturer’s
component significantly. automated production line.
The customer states that only SCHUNK products The sigPOD™ PSV software was configured using a
made it possible to get the stamped air bag component simple setup wizard to perform an automated end of line
through all seven stations within 3.5 seconds and also audit test on the standard automotive oxygen sensors.
get it inspected with a vision system throughout the This included setting sampling rates, precise triggers,
manufacturing process. Transfer Tool Products has waveform calculations and signature based feature checks
tuned the servo motor driving the SCHUNK HSB unit to execute the most precise quality analysis available.
achieving a speed of 35 feet per second. With this machine The results of each sensor test were archived to a
having millions of cycles without failures, the high qualityworX™ database where a simultaneous review
speed application can produce over 7000 parts an hour. of thousands of waveforms is performed and stored for
Overcoming the limitations of other transfer presses, future use.
SCHUNK has proven to be the perfect choice. Achievement: Precise, fast, and repeatable results
without sacrificing throughput or quality integrity.
Information captured by the qualityworX™ database
can be used to determine production limits, provide
complete serialized traceability, deliver evidence of
quality conformance and provide valuable insight into
production processes.
SCHUNK Inc. Features & Benefits:
211 Kitty Hawk Drive 䡲 serialized traceability 䡲 waveform calculator
Morrisville, NC 27560 䡲 stand alone capability 䡲 discrete logic I/O
Phone: 919-572-2705 䡲 dynamic advance 䡲 ethernet IP capable
Toll Free: 800-772-4865 feature checks 䡲 available FFT analysis
Fax: 919-572-2818 䡲 full waveform analysis
E-mail: info@us.schunk.com
www.schunk.com Sciemetric instruments
inquiries@sciemetric.com
www.sciemetric.com
1-866-900-7054

Thinking Outside
the Box
S
ealant Equipment & Engineering developed the
Multi-Function Gun (MFG) to improve the dispens-
ing quality and application speed of 1-component
heat cure sealers used in automotive assembly plants and
tier-1 suppliers. Prior to the introduction of MFG appli-
M
cators engineers had to select one type of bead profile anaging down time in high production operations
(spray, stream or ribbon) per dispensing robot or have is a continuing challenge. Nowhere is this more
multiple valves on one robot to perform multiple bead important than in the automotive sector. Often it
profiles, each with a different tip. Having multiple valves requires investigating and implementing different meth-
and hoses on a dispensing robot is cumbersome, costly ods to accomplish the same task. In this case the task
and difficult to maneuver inside a vehicle. resulted in replacing a competitor’s marking laser with
With the support of automotive companies and robot micro-percussion technology.
integrators worldwide Sealant Equipment created 5
different models of the 2600-022 series Multi-Function APPLICATION: Marking aluminum cylinder heads with
Gun to comply with various customer specifications. The 18 human readable characters and a Data Matrix code
plain basic model has evolved into a 3-Tip applicator, faster than the laser marking system.
a 3-Tip with material re-circulation and a 5-Tip model
with various accessories. The 3-Tip Multi-Function Gun PROBLEM: The competitor’s laser was unreliable with
uses three (3) KISS Valves with individually selectable 20 hours of downtime over an 8-month period and it
dispense tips. The 5-Tip Multi-Function Gun uses five proved difficult to troubleshoot and support.
(5) KISS Valves with individually selected dispense tips
to dispense the right bead profile. SOLUTION: Using the high speed Technifor XF510Cp
KISS No-Drip® high-pressure dispense valves are ideal the complete marking was accomplished in less time
for the automated application of pumpable materials. The than the laser. Only a fraction of the marking speed’s
needle, seat and flow-through design technology enables the capacity was needed in this application.
KISS valve to perform longer with high volume applications,
frequent on-off cycles per part and abrasive materials. BENEFITS SUMMARY: The pricing was 1/5 the cost of
KISS valves incorporate a carbide hardened needle/ the laser, cycle times reduced, and reliability improved.
ball and carbide seat with an abrasion resistant seal to The solution was implemented in less than one day.
further increase its life cycle and reduce down time.
For more information on automotive applications Technifor offers a full product range of micro-
and capabilities visit http://www.sealantequipment.com/ percussion, scribe, and laser marking technologies as well
automotive.htm as free in plant analysis and sample processing. Customers
To view automotive application videos visit http:// have free access to 24hr service, repairs may be turned
www.sealantequipment.com/videos.htm#AutoIndustry around in one day and spare parts are in stock.
Technifor, Inc
Sealant Equipment & Engineering, Inc. 704-525-5230
45677 Helm St., Plymouth, MI 48170 tfinc@usa.technifor.com
ph: (734) 459-8600 Sales@SealantEquipment.com www.technifor.com
www.SealantEquipment.com

CASE STUDY
Belting out Belts Automotive
Manufacturer
Improves Component
Assembly with TURCK
Weld Nut Sensor
A
n off the shelf ball screw actuator and controller
has made it possible for one operator to produce six
times as many drive belts per shift. In the past, when
operators manually indexed a knife to cut the belts, they
could produce about 100 per hour. Stock Drive Products,
New Hyde Park, New York, the company that produces
the belts, had the idea of automating this difficult and
T
expensive job. A sister division, Techno, Inc. also based o determine if a nut on a bracket was in the right
in New Hyde Park, created a design that uses standard spot during component assembly, a large automo-
components to completely automate the job. The new belt tive manufacturer used to manually “eyeball” or
slicing machine produces 300 belts per hour with mini- use expensive cameras to confirm the nut was properly
mal manual intervention, making it possible for a single placed. The correct placement of the nut is essential to
operator to run two of the new machines simultaneously. ensuring that the design of the vehicle is unhindered and
Quality is also improved by the consistency of the auto- eliminates the costly alternative—scrapping the entire
mated slicing operation. “The new automated machine assembly up to that point in production.
substantially reduces the cost of producing timing belts The manufacturer now uses TURCK’s magnetic-
while demonstrating how small, low-cost automation inductive weld nut sensor to provide accurate, efficient
projects can provide a big payoff,” said Bob Gaulrapp, detection—at a more cost-effective price than alternative
Manufacturing Manager of Stock Drive Products. solutions. In this application, the nuts are attached to
The result, according to Perry Pierides, Manager a bracket and detected by the TURCK sensor prior to
of the Belt Department, is a dramatic performance welding. After the nuts are detected, the bracket is welded
improvement. “The operator simply puts the sleeve on to the floor pan of the vehicle, where other assembly
the machine and enters the program on the controller for components are then fastened to the nut.
the width of belt that they want to produce,” Peirides said. During set up, the nut and bracket assembly is
The machine paid for itself in a matter of months and fitted over TURCK’s weld nut sensor. This sensor has
continues to provide major manufacturing cost savings. been programmed—using a simple teach function—
Meanwhile, the belt slitting job has gone from one of the to differentiate between the sheet metal and the nut,
least to one of the most desirable in the shop.” so no additional programming is needed for proper
functioning. The weld nut sensor saves configuration
Techno Linear Motion Systems time and company money by providing a simple, reliable
2101 Jericho Turnpike and affordable tool to improve assembly processes on the
New Hyde Park, NY 11040 plant floor.
(516) 328-3970
Fax (516) 358-2576 TURCK
Contact: Joe Griffin, Linear Motion 1-800-544-7769
Products Sales Manager www.turck.us
jgriffin@techno-isel.com turckusa@turck.com
www.technoautomation.com

Conductix-Wampfler WEISS North America

Assembly System
C
enterline (Windsor) Limited Machinery Division
is a full service integrator/machine builder of tube
processing, metalworking, and welding systems.
Centerline had a need for a heavy duty rotary positioner
for their automotive body and frame robotic weld cells.
The need stemmed from increasingly heavier loads than
their current solution could accommodate.
I
n Niepolomice, Poland, MAN Nutzfahrzeuge Group Weiss North America, Inc designed and manufactured
built the most modern truck plant in Europe, which, the CR series of barrel cam index tables for just such heavy,
by 2010, will assemble 15,000 trucks annually in a dynamic loads. The Weiss solution fit Centerline’s needs
continuous flow. A critical part of the assembly line is an due to the ability to index their loads quickly, accurately,
integrated compressed air, electric power, and tool trans- and with extremely fast E- Stop times. The CR table
port system designed by Conductix-Wampfler. “With was also advantageous due to its compact design, zero
MAN, we developed a complex roof structure to support backlash, full programmability, and maintenance free
and power all assembly tools along their respective line operation for life.
segments”, explains project manager Daniel Schlösser. The technology behind the Weiss CR tables is the
The system gives the assembly operator great flexibility continuous engagement of multiple cam followers at all
all along the line. times. Traditional tables will have one or two followers
A key component is the extruded aluminum W5-traxX engaged in the cam, while the CR has a minimum of five
“media rail.” This unique rail has a compressed air pipe and up to eight depending on the table size. This gives the
formed within the extrusion. Compressed air, electric CR an enormous mechanical advantage over traditional
power, and data lines are carried from the rail to the cam indexers and gear driven positioners.
assembler via an integrated cable chain system. The Centerline has now integrated the Weiss solution into
outside of the rail accommodates moving transports for their REV-TEC™ product line to provide customers with
assembly tools. The system can be expanded to include the optimum in rotary table solutions. They currently offer
a contactless system to provide the exact position of the five table sizes for payloads ranging from 500-9000 kg.
carts and automatic data collection. Their low profile, robust designs are offered with secondary
“The high load capacity, rigidity, and operational trunions and many practical options that enable the REV-
flexibility of the system allow us to use crane systems, TEC™ tables to satisfy virtually any automation need.
handling technology, lighting, and compressed air supply The principal benefits to this product line include: zero
systems wherever needed. The system can be adapted to backlash, fast index and E-Stop times, extremely smooth
changing requirements. Conductix-Wampfler planned and accurate operation, infinite positioning capabilities,
and coordinated the whole project, assembled the steel maintenance free operation and Weiss’ 5 year limited
framework, lamp controls, and stationary compressed air warranty support. Details of the unique REV-TEC™
supply,” says MAN plant manager Marc Sielemann. product line can be found at www.cntrline.com.
Conductix-Wampfler Weiss North America, Inc.

Mike Bjornstad, Handling Products Market Manager 3860 Ben Hur Ave
1-800-521-4888 (1-402-952-9327) Willoughby, OH 44094
mike.bjornstad@conductix.com www.weissna.com
888-WEISSNA (934-7762)

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Products
Modules Grip and Rotate
New DGP404 parallel grip and rotate modules Safety Laser Covers Complex Areas
with T-slot guides can be used in high-load SZ Series Type 3 safety laser scanners allow
users to configure protection areas anywhere,
even in complex-shaped zones and dangerous
areas. The scanners’ compact body and light
weight help facilitate installation and save
space without compromising quality or detec-
tion range. A built-in muting function lets the
scanner ignore certain areas of the protection
zone to allow for passage of targets. Unlike
light curtain muting, scanner muting results
in a much tighter protection zone, minimizing
dead zones around passing targets.
Keyence Corp.
www.keyence.com/sz
888-539-3623
SCARA Line Features Curved Arms

automation applications that require parts to The G3 line of compact SCARA robots provides high
be sorted and rotated 90 or 180 degrees. The speeds and precision for use in a wide range of assembly
grippers are compact, and the T-slot guides applications. The robots are available with reaches of
help absorb large forces and moments. The 250, 300 and 350 millimeters. Class 10 cleanroom and
modules are available in six different con- ESD compliant configurations are also available. G3
figurations, including those that perform both robots include a curved-arm option to maximize work
inside and outside gripping. envelope usage. By employing a curved arm, a G3 with
Techno-Sommer Automatic a 350-millimeter is able to match the motion range of a
www.techno-sommer.com larger 400-millimeter SCARA robot, without occupying
800-819-3366 a larger footprint.
EPSON Robots
www.robots.epson.com
Valve Provides Micrometer Control 562-290-5910
The Model 455 pneumatically operated, two-
way pinch valve features micrometer control
over the flow rate, ensuring that materials Bulk Systems Dispense
are dispensed repeatedly and accurately. The
Sealants, Adhesives
New line of small ram bulk supply systems can be used to
transfer sealants and adhesives from 20-, 30- and 60-liter
containers. The systems are available with Check-Mate
pumps, which feature a quick-disconnect coupler for
easy maintenance, cartridge throat packings for easy
servicing, and optional MaxLife coatings on all rods and
cylinders to increase the life of the pump.
Graco Inc.
www.graco.com
877-844-7226
New Linear Bushings Available

New pillow-block-type linear bushings are avail-
valve features proprietary over-stroke adjust-
able with clamp levers or MX-type self lubrica-
ment, positive shutoff and disposable inert
tion. The bushings with clamp levers are available
wetted parts, enabling users to obtain millions
in a range of sizes and in single or double versions.
of cycles from a single piece of tubing. The
The self-lubricating bushings offer up to 2.5 times
valves can be easily integrated into an auto-
the durability of non-greased bushings.
mated assembly line and can be fitted with a
Misumi USA
number of different dispense tips and spray
www.misumiusa.com
nozzles.
800-681-7475
Tridak LLC
www.tridak.com
860-626-6700

Tool Measures Torque, Angle needed. A three-point locking handle securely
The CTA2 digital torque and angle wrench latches doors when closed.
combines two tools in one. Operators can IAC Industries
enter snug torque and angle data either through www.iacindustries.com
714-990-8997
Safety Systems Enable Leaner Cells

The SafeMove system is a software- and
the tool’s keypad or via PC software. Upon electronics-based safety system that is
reaching the desired snug torque, the display directly integrated into a robot’s controller. especially beneficial in applications that are
automatically changes from torque to angle It provides safety rated supervision of robot sensitive to heat. The system includes a unique
mode. When approaching the set angle an motion, enabling leaner robot cells and more adjustment feature that provides user control
intermittent buzzer sounds, and when target collaborative applications where robots and of light intensity to assist in process validation
angle is achieved a blue lamp lights and a operators can work more closely together. and control.
steady buzzer sounds. The system offers a host of leading-edge DYMAX Corp.
Tohnichi America Corp. safety functions and reduces the need www.dymax.com
www.tohnichi.com for traditional safety equipment, such as 877-396-2988
847-272-8480
Spin Coat with Ease
Vacuum Ejectors Provide Reliability The SCS 6800 spin coater makes it easy to
SEAC-RP model vacuum ejectors are configured accurately apply liquid coating materials such
specifically for use with vacuum spiders and as photoresists, polyimides, metal-organics,
feeders, like those used to manipulate metal dopants, silica films and most organic and
sheets in pressing applications. The ejectors aqueous solutions. The system’s proprietary
circuitry provides precise control of spin
light curtains, safety relays, mechanical

stops, mechanical position switches and
protective barriers.
ABB Robotics
www.abb.com/robotics
ensure reliable decentralized vacuum generation Gantry Stage is Compact, Precise speed, and acceleration and deceleration rates.
and use a minimum of compressed air. They Compact, low-cost, two-axis linear stepper It is controlled via an easy-to-use three-button
feature extremely short gripping and blow off motor gantries offer low force, high speed, high keypad and an LCD display on the front panel.
times, thereby facilitating short cycle times in repeatability, zero backlash and long system life. Programmable and nonprogrammable units
an automated setting. The systems are capable of very precise position, are available.
Schmalz Inc. velocity and acceleration control when integrated Specialty Coating Systems
www.vacuworld.com/us with a microstepping drive and indexer. They can www.scscoatings.com
919-713-0880 800-356-8260
Workbenches Available Conveyor Drive Is

with More Options Compact, Easy to Use
The Workmaster storage cabinet line now The new iDrive conveyor drive integrates the
includes seven new pedestal configurations motor, gearbox and motor controller in a sin-
providing wide, large-capacity drawers gle, space-saving package. The drive, which
in combination with split-door cabinet is available on the 2200 series of conveyors, is
compartments. The cabinet pedestals can be
used with a variety of worksurface types, be used in a wide range of applications, including
including laminates, maple butcher block and laser marking, inspection systems, pick and
stainless steel. The cabinets offer up to 12 place systems, assembly, rapid prototyping, wire
cubic feet of storage that can be divided up as bonding and fiber optics.
H2W Technologies Inc.
www.h2wtech.com
888-702-0540
Lamp Provides High Output, Low Cost a variable speed system that is also reversible
The BlueWave 75 is a high-power spot lamp for maximum application flexibility. Control
that provides a combination of low operating switches are easy-to-use, conveniently located
cost with high-intensity output to accommo- and protected by a high-impact case.
date a wide variety of bonding applications. Dorner Mfg. Corp.
The lamp transmits less energy onto sub- www.dorner.com
strates, resulting in cooler cures, a feature 800-397-8664

An Industry-focused market research company
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Advertisers Index
Alcoa Fastening Systems................................. 27 ProLine ....................................................................4
AMSP All Metric Small Parts .......................... 40 Promess ............................................................. IFC
ATI Industrial Automation ....................................9 Quality Bearings & Components .................... 37
Assembly Technology Expo 2009.....................7 Saejong Industries ............................................. 40
CDS Corp. .......................................................... 29 Sankyo .................................................................. 14
Clear Seas Research ........................................ 62 Schatz USA Inc. ................................................. 41
Conductix-Wampfler.......................................... 37 Scheugenpflug ................................................... 36
DEPRAG Inc. ....................................................IBC Schleuniger Inc. .....................................................8
Dymax ................................................................... 31 Schmidt Technology .......................................... 17
Edgewater Automation ..................................... 13 Schunk Inc. .......................................................... 22
EFD ..........................................................................1 Sciemetric .....................................................10, 11
Ellsworth Adhesives ...................................30, 33 Sealant Equipment & Engineering ................. 35
Gloves Online ..................................................... 41 Technifor ............................................................... 33
Hernon Manufacturing ...................................... 28 Techno .................................................................. 23
I & J Fisnar Inc. ...................................................BC Techno Sommer ................................................. 30
Lista International Corp. ......................................5 Turck .........................................................................3
Origin Technologies........................................... 32 Visumatic Industrial Products Inc. .................. 16
Pfeiffer Vacuum................................................... 12 Weiss North America ........................................ 35
This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.
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Leading
Lean
Jamie Flinchbaugh
Partner
The Lean Learning Center
Novi, MI
Solve the Right Problem
E
veryone solves problems must respect the impact of the right problem statement at least 50
every day, at home and problem statement. Wrong trajec- percent of the time.
at work. But a common tory; wrong destination. The third pitfall in problem
blind spot is right at the Consider the difference in statements is jumping the gun
beginning: the problem impact from two very similar on too many assumptions before
statement. No matter how problem statements: How do I get the problem statement is created.
well we do at solving a problem, Joe to be a team player or, how do We insert unexamined causes
if we solve the wrong problem it I develop a working relationship and solutions into the problem
was a waste of effort—and lean is with Joe? The first problem statement, closing us off to many
about eliminating waste! We must statement is all about the other possibilities. The earlier example
be sure we are solving the right person, but the second problem of “we don’t have enough ovens”
problem. is an example of putting
Often, engineers make
things more complicated
Before you start down a path, the solution in the problem
statement. There is only one
than necessary. Consider the
example of the NASA space
make sure you’re setting off solution to that problem—buy
more ovens. It immediately
pen. During the 1960s, NASA on the correct journey. Wrong closes you off to many
possibilities. When we assume
focused a major program on
developing a pen that would trajectory; wrong destination. too much too early, we limit
write in zero gravity, while what we can learn through
the Soviet space program used the statement includes the problem observation and examination.
much simpler and already-invent- owner, giving that person infinitely I have two recommendations
ed pencil. more power to solve this problem. for improving problem statement
I don’t know for sure because Here’s another example: We don’t development. The first is to write
I wasn’t there, but I strongly sus- have enough ovens or, we don’t down the problem statement.
pect this came about because of have enough oven capacity. The Seeing the words on paper or,
a miss in the problem statement. first problem statement only leads even better, on a whiteboard, will
The Americans were working on you to buy more ovens. The second be a big help in evaluating and
this problem: How do we get a pen helps focus on how you might be improving the problem statement.
to write in zero gravity? The So- wasting oven capacity. The second is to pause and ask for
viets were working on a different The second pitfall is getting input, or offer coaching, on the
problem: How do we write in zero locked into the problem statement problem statement before going
gravity? It seems like such a small, as though it is written on a stone too far. Ask your team, “Are we
subtle difference, but it had a huge tablet. We must be willing to adjust sure we have the right problem
impact on what work followed. our problem statements. This statement?” This will increase
The problem statement estab- doesn’t mean our original problem critical thinking significantly. Start
lishes our trajectory. If two people statement was wrong. Writing a with your own problems—write
depart the same location on a trip, problem statement is an iterative them down and get input. Lean
and only 5 degrees separates their process—problem statements are begins with you!
trajectory, they will be in drasti- changed because we learn stuff
cally different places in a matter of through the process of examining Email Jamie with comments via
hours. We underestimate how pow- the problem. In my experience jamie@leanlearningcenter.com.
erful the problem statement can be, of coaching executives on lean For his recommended books
and that is pitfall number one. We thinking, we have to modify a see tinyurl.com/leadinglean

SCREWDRIVING AUTOMATION AIR MOTORS POWER TOOLS
TECHNOLOGY
V E R S A T I L E M I N I M A T® - E
INLINE HIGH TORQUE

—— Up to 160 inch lbs torque capacity
—— Torque-Holding-Time which
compensates for relaxing joints SFM with a
—— Push to Start Minimat®-E mounted
—— Ergonomic Design to a rotary index table
—— Non Slip Housing
[
HANDHELD
MINIMAT ®- E Angle-Head STATIONARY
[
Now available with up to
221 in. lbs. torque MINIMAT ®- E
MINIMAT ®- E Servo Angle-Head 159 in.lbs. torque
531 in.lbs. torque MINIMAT ®- E Servo
2,400 in.lbs. torque
PISTOLGRIP
—— All the functions of the
original inline Minimat®-E
—— Light Weight - starting
at 1.28 lbs
—— Ergonomic Design
—— Trigger Start
—— Non Slip Housing
DEPRAG, INC.
640 Hembry Street
Lewisville, Texas 75057-4726
972 221 8731 main
972 221 8163 fax
Catalog request:
catalog@ depragusa.com
General e-mail:
mailbox@ depragusa.com
aqy
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Automation Profiles . . . . . . . . . . . . . . . . . . 8 Leading Lean . . . . . . . . . . . . . . . . . . . . . . . 64

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