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Fastening solution slashes assembly time

Edited by the Engineeringtalk editorial team Oct 13, 2003

Serco Ryan application engineers have developed a highly efficient fastening solution for one of the world's largest motor manufacturers' latest line in control gear.

Serco Ryan application engineers have developed a highly efficient fastening solution for one of the world's largest motor manufacturers' latest line in control gear.

Not only did the design significantly cut assembly time through reducing the number of components, but also cut stocking costs and facilitated maintenance of the range of products.

A combination of Serco Ryan's expert knowledge and impartial advice has also led to further reduced costs through a more integrated component supply solution.

"Many traditional fastening techniques used in engineering and manufacturing have been continued way beyond their practical lifespan in today's cost competitive markets", explains Serco Ryan Application Engineer, Jason Williams.

By keeping up to date with current developments in fastening technology and holding one of the widest stocks in Europe, our technical department can give companies crucial advice at the design stage to ensure that they are maximising the role fasteners can play in making their product assembly lines more efficient".

It was for these reasons that Serco Ryan application engineers were asked by the company to provide a solution for assembling control panel terminals, which would reduce the number of components and the number of different types being used while still meeting safety regulations.

The traditional method for connecting three terminals to the steel control panel would have required a total of 18 fasteners including six different types, making assembly time lengthy and repairing or servicing the units difficult.

"The design brief had strict parameters in which to work", explains Williams.

"We were asked to fit an M5 bolt through the mild steel baseplate to provide the connection stud without letting bolt heads protrude out of the back and eliminate the chance of the whole unit rotating in the hole during assembly or maintenance.

The casing was too thin for a countersunk head bolt so we recommended that a type of clinch stud be used and supplied to the baseplate manufacturers, who would be better equipped to press them into the casing prior to delivery.

Brook Crompton could then reduce the number of production stages, component costs, time and the need for investment in new equipment".

Further cost and labour savings were made by recommending a type of nut that has an inbuilt compression washer, therefore removing the need to fit the standard and lock washers traditionally required.

Williams explains: "We were able to find nuts that were strong enough to replace the locking nut but fitted inside the copper grip washers mandatory for these types of electrical connection.

The nuts reduced the chance of other fasteners coming loose when terminals were removed from the stud and also created a uniform appearance".

These two recommendations halved the number of fasteners and operations required by the company to fit each terminal.

Fewer components also improved maintenance procedures, which is a particularly beneficial as connections regularly have to be removed to service the motors and often in the most challenging conditions.

Serco Ryan's application engineering service is backed by over 80,000 separate fastener ranges and includes full supply management systems including JIT/DLF and Kanban with delivery available anywhere in the UK.

Impartial advice and manufacturing cost reduction studies are also available from Serco Ryan branches throughout the UK.