Improving Torque Control in Circuit Breaker Assembly

This manufacturing facility needed to improve torque accuracy and process reliability in circuit breaker assembly

A high-volume circuit breaker production facility in Latin America was experiencing recurring quality issues caused by inconsistent fastening tools. Frequent calibration requirements, incorrect torque delivery, and component damage were affecting productivity and profitability.

By implementing INSIGHTqcx controllers and QXX cordless tools with integrated traceability, the facility achieved greater process control, eliminated fastening-related damage, and increased productivity by approximately 9%.

Key Facts

Industry: Electrical Manufacturing
Application: Low-Voltage Circuit Breaker Assembly
Solution: INSIGHTqcx + QXX Tools
Productivity Improvement: Approximately 9%
Traceability: Full tightening records with barcode integration
Result: Zero screw and plastic component breakage attributable to fastening process issues

Existing assembly tools were creating quality issues, rework, and production inefficiencies

The facility manufactures low-voltage circuit breakers for a large regional market and relied on three clutch tools per workstation for assembly operations. These tools lacked the precision required for critical fastening applications and required frequent calibration.

Several assembly points required tightening values as low as 0.5 Nm, but the existing fastening equipment regularly applied excessive torque. This resulted in broken screws, damaged plastic components, and increased material waste.

Additionally, one critical fastening operation depended on a hydropneumatic tool. Because compressed air availability and consistency varied throughout the facility, some tightenings were completed below the required specification, creating quality and reliability concerns.

These issues led to:

Process failures and rework
Reduced operator efficiency
Component scrap and replacement costs
Limited visibility into fastening performance
No comprehensive tightening traceability for audits or process management

A connected fastening solution provided precision, repeatability, and complete traceability

To improve fastening performance, the facility deployed:

2 INSIGHTqcx controllers
12 QXX cordless precision fastening tools
Tool range covering tightening requirements from 4 Nm to 24 Nm
Barcode scanning integration for serial-number traceability

The connected fastening system enabled complete management of every tightening event across the assembly process.

Key capabilities included:

Precise torque control
Consistent tightening performance
Real-time process monitoring
Tightening result traceability
Historical data storage for audits and reporting
Product serial-number association through barcode scanning

The implementation ensured that every fastening operation could be validated, recorded, and reviewed, significantly improving quality assurance and process visibility.

The facility eliminated fastening-related damage and increased productivity

Following deployment, the manufacturing team achieved measurable improvements across quality, productivity, and process visibility.

Business Results

Approximately 9% increase in productivity

Reduced disruptions caused by fastening errors
Improved operator efficiency through more reliable tooling

Elimination of fastening-related component damage

Screw breakage reduced to zero
Plastic component damage reduced to zero
Lower material waste and scrap costs

Improved quality assurance

Greater tightening consistency and repeatability
Reduced risk of under-torque and over-torque conditions

Enhanced reporting and traceability

Complete tightening records linked to product serial numbers
Improved audit readiness
More comprehensive management reports based on collected fastening data

INSIGHTqcx Controllers

Advanced fastening process control, monitoring, and traceability.

QX Cordless Precision Screwdriver

Accurate, repeatable torque delivery for critical assembly applications.

“Our assembly process is now more reliable, and we can offer better solutions to our customers.”

— Manufacturing Manager

Electrical Manufacturing: Circuit Breaker Assembly Case