Improve Torque Traceability & Production Output

Summary

A global manufacturer of mission-critical electrical components needed to improve torque consistency and traceability while doubling production capacity.

By implementing Ingersoll Rand controlled torque tools and IQI systems, the operation eliminated variability, ensured full traceability, and increased efficiency.

Key Facts

Industry: Industrial Manufacturing / Electrical Components
Application: Breaker Assembly for Data Centers
Tools Used: Ingersoll Rand QX, RTS, and IQi Controlled Torque Systems
Initial Investment: ~$200K (scaling to ~$500K)
Key Outcomes: 2,500 → 5,000 units/month

The Challenge

The manufacturing operation faced critical limitations in assembly precision and quality validation within a high-performance production environment.

Key Challenges:

Lack of torque control
- Pneumatic and conventional electric tools could not ensure consistent torque
No joint traceability
- Inability to validate assembly quality for critical infrastructure applications
Production constraints
- Capacity limited to ~2,500 units/month with a requirement to double output
Process variability
- Manual and uncontrolled tools introduced inconsistencies
Strict customer requirements
- Needed to comply with rigorous standards from major technology end-users
Ergonomic challenges
- Tool handling and repetitive motion increased operator fatigue

These issues limited scalability, created quality risks, and reduced operational efficiency.

The Solution

A comprehensive controlled torque ecosystem based on Ingersoll Rand technologies was implemented to standardize assembly and enable traceability.

Solution Components:

QXX Pistol Grip Tools
- Enhanced ergonomics and accessibility
RTS Controlled Torque Tools
- Replaced impact tools to deliver consistent and repeatable torque
IQi Electric Screwdrivers with Controllers
- Provided:
  - Real-time torque monitoring
  - Joint-level traceability
  - Automated data recording and validation
Industrial Balancers
- Reduced operator fatigue and improved tool maneuverability
Application-Specific Configuration
- Torque parameters optimized for each fastening point
Operator Training Programs
- Supported successful adoption of digital torque systems

The Results

Measurable Outcomes:

Full torque traceability across critical joints
Elimination of process variability
Improved product quality and reliability
Increased operational efficiency
Progress toward doubling production capacity (5,000 units/month)
Enhanced compliance with audit and validation requirements
Significant ergonomic improvements

“The implementation of IQi tools with traceability enabled us to ensure assembly quality in critical applications.”

Project Process Engineer

iqi_ensuring-assembly-quality-in-critical applications.png

QX Series™ Precision Screwdrivers

Ergonomic, high-precision fastening designed for repeatability

RTS Controlled Torque Systems

Replace impact tools with consistent, controlled torque output

IQi Series Electric Screwdrivers

Enable full traceability and real-time torque monitoring

industrial balancer improved ergonomics and reduced operator fatigue in the workplace

Industrial Balancers

Improve ergonomics and reduce operator fatigue

“We can now record and validate every torque applied, meeting our customers’ requirements.”

Production Supervisor

Ingersoll Rand RTS reduced the need for multiple tools for different applications on the assembly line

Does this challenge resonate with your business?

Contact an Expert

Looking to improve assembly quality, reduce rework, or scale production capacity? Contact an expert to learn how controlled torque solutions can optimize your manufacturing operations.

Industrial Manufacturing & Electrical Components Case