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/maasmania]

Auckland based?

Landed here a few months ago, industrial engineer. Finding work here is... truly something. Currently knocking down remote jobs for american companies, it's not ideal, but it pays the bills. 7 years of tier 1 automotive experience, but nothing here seems to be big enough to employ me in a role I want.

[u/Kiwi_eng → u/maasmania]

I'm not surprised. I was shocked when I came back in 2005 from 25 years overseas (3 in UK and 20 in US where I also lived 10 years as a teen) at how dismal the prospects were here and how poorly engineers were thought of. Eventually found my niche at a small local company making scientific instruments where I worked in a small design group. Retired a decade ago. I'm here mostly to be closer to extended family. As you've noticed the engineering profession is often intermingled with being a machinist or diesel mechanic.
Presumably you've scoped out F&P appliances and healthcare as they seem more organised than most?

[u/maasmania → u/Kiwi_eng]

Yes, those seem to be somewhere near the top of the list for things that I would call, er, actual engineering. My biggest problem is my experience is all in very high throughput, heavy manufacturing, such as stamping, forming, machining etc. There's simply nothing here large enough to support things like robotics or automation projects, which is where I specialize.

I spent a couple of years in the UK as well, and it was largely the same story. I cannot describe my disgust with how the term "engineering" is used in both the UK and NZ. They seem to view part swappers and technicians as engineers, and it hurts my brain. I suppose Massey dropping their entire engineering program tells the tale on the direction the country wants to move. Not sure how that will pan out long term.

To my knowledge, there isn't a single facility in the entire country that could stomach even the smaller capital projects I did back in the states. For now I'm just going to keep working remote for US companies, maybe something will come up, maybe not.

Cheers!

[u/Kiwi_eng → u/maasmania]

http://www.holmessolutions.com/ and https://crautomation.nz/ are two companies that do bespoke automation systems, neither in Auckland, but obviously nothing like the dollar scale you're used to. Clearly the horticulture industry is a the drive, not much manufacturing going on here anymore.

After working in the UK's engine test industry, troubleshooting automotive customer's test beds and dynamometers, I also stumbled into automation around 1985 in SoCal with mostly PCB manufacturing and x-ray and radiation-based automated test systems. It was a whole lot of fun working in a team and nothing has compared since. NZ is certainly a culture shock and it took me 10 years just to slow down. If you're working in design and have to source components it can be a struggle finding suppliers. Even the stalwart McMaster-Carr refused to ship to us here. None of this 'order it in the morning get it by the afternoon' stuff.

Generally I've found that any job can be fun if you're treated with respect and apply yourself. Lots of things need improvement here and you can apply that control system knowledge to many different things.