Observations and Solutions
During a technical line review of a customer’s facility, the Field team observed the components and methods of manufacturing used to assemble an engine. The following observations were made with corresponding solutions:
- The Field team observed assemblers applying adhesive to several bolts during assembly
- Takes approximately 5 seconds to apply adhesive
- Current adhesive is not recommended for use on higher temperatures
Solution: Eliminate adhesive completely which also saves cost of time applying adhesive
Total opportunity: $219,450
- The current practice is to apply pipe sealant to fittings during assembly
- Takes approximately 8 seconds to apply sealant
Solution: Use pre-applied adhesive
Total opportunity: $55,550
- The current practice is to use split lock washers on various fasteners
- Takes approximately 2 seconds to locate and assemble wash to fastener
Solution: Eliminate split lock washers
Total opportunity: $21,450
- The Field team observed the assembly line process for installation of a flywheel using a torque wrench.
- Wrench needed adjustments several times and a star pattern was used for installation
Solution: Use a standard bolt pattern and a have a torque wrench available at each station with correct torque
Total Opportunity: $239,800
- Pre-drilled and tapped holes used only on certain models.
- When they are not used the cost of drilling and tapping are wasted
Solution: Use thread forming fasteners to form the thread when needed
Total opportunity: $41,250
Results
The recommended Field solutions improved quality and reduced total costs by:
- Better consistency & reliability
- Reduced assembly time
- Part and assembly tool consolidation
- Part and Process Standardization
- Improved Assembler and End-User Safety