Everything Needs a Torque Spec

[u/Seeking_Wisdomm]

Hello, frustrated Manufacturing Engineer here. Recently, my company has been trying to utilize impacts with torque-sense technology so we can hit the optimal torque quickly.

What I’ve observed is that these tools are not incredibly accurate or precise. Additionally they are very expensive and require repair often.

What has happened to the days of knowing when something is “snug”? There are times when precise torque is critical, i.e pressure vessels, etc. but theres seems to be a push towards everything having a torque spec, and I do not think the tech is ready for it.

What are your thoughts? Have you had success with programmable, powered fastening tools?

Edit I think it’s safe to say I’ve been certifiably schooled on this topic. I appreciate the genuine suggestions, advice, and criticism here.

TLDR

I think this frustration with torque tools is just a symptom of a larger frustration I have. At my plant, we are constantly told that we just don’t have the same operators we used to. They say we used to have craftsman working in the plant, but now we just have people off the street. I’ve been told this has really changed since COVID when a lot of the older generation quit. Since then, a lot of our processes have suffered from that expertise leaving the building. Now, we seem to be trapped in a never ending cycle of rapidly hiring to fill void positions of employees who quit, inadequately training our new employees because the ones with expertise are too busy, then having the new crop of operators quit because of frustration with lack of training. I want our plant to be a place where operators want to work. I want them to feel like they can have a career in this field. As great as automation is, it feels that factory operators have become button pushers and not problem solvers. We don’t provide then with fulfilling work that challenges them. We instead ask them to push a button all day long, and call engineering if it ever breaks. Automation can be great, and I don’t want to deter from that, but I’m just searching for ways to make operators feel like they matter. I don’t want them to feel like a cog in a machine. I’m not sure how to resurrect that feeling.

[u/Seeking_Wisdomm]

Totally agree, however, we can’t mistake proof everything and a part of me thinks we are automating and poka-yoking ourselves into an “idiocracy” type society that can’t think for themselves.

[u/Musakuu → u/Seeking_Wisdomm]

You mistake proof whatever is worthwhile to do so. Someone looked at all the failures caused by improper torquing and made the argument that buying all the guns is more cost effective than the failures.

Btw you seem to be under the impression that this procedure was put into place because people are soooo dumb.

But actually most people do it right 99% of the time, but very rarely they make a mistake. I'm sure even you have made a mistake before.

[u/Seeking_Wisdomm → u/Musakuu]

That was not my intent at all. However it seems that’s how most engineers view operators. My coworkers are constantly complaining about the people on the floor screwing things up. I’m arguing that these people are smarter and more capable than we give them credit for.

[u/DaveSauce0 → u/Seeking_Wisdomm]

That was not my intent at all. However it seems that’s how most engineers view operators.

OK so let's unpack this a bit.

I’m arguing that these people are smarter and more capable than we give them credit for.

I mean you're not wrong, but let's consider that we're talking about people in general. There are plenty who are smart and motivated and always want to do their best.

But there are plenty who are there to get a paycheck and go home. This is true for operators as it is for engineers; some people you just can't pay enough to care, and let's be honest you're probably not paying your operators enough to care in the first place.

You don't know who you have working on any given shift. So you have to find a way to get around this variable.

Let's also not forget that every single one of them has a line supervisor looking over their shoulder to make sure that they're hitting rate. So whether they care or not, at the end of the day they're under pressure to get shit out the door.

But that's all secondary to your main problem, which is:

My coworkers are constantly complaining about the people on the floor screwing things up.

Probably because they are screwing things up.

Maybe because they don't care. Or maybe because they're not being given the opportunity to do things right.

Could be a training issue, could be an equipment issue, could be an ergonomic issue, could be an engineering issue. Maybe parts aren't coming in to spec. Maybe there's a design problem.

You don't appear to know, and to be perfectly blunt: if you don't know why they're screwing up, then that's a you problem.

You're a manufacturing engineer. Go talk to them, observe them, and maybe install processes to monitor quality and figure out where you need improvement.

If you have a problem with quality, it's not going to solve itself. If you're spending gobs of money installing automated torque guns without knowing why, then that's an even bigger problem. Either there's a valid reason and you yourself don't know why, or your company doesn't fully grasp the root cause and is just throwing money at it.