Improve Torque Safety and Throughput in Assembly

This assembly team needed to reduce ergonomic risk while improving torque consistency in a high-volume environment

A multi-site trailer manufacturing operation faced safety risks and inconsistent results from manual torque processes.
By implementing Ingersoll Rand QXM torque multipliers with QCXD controllers, the team improved ergonomics, throughput, and torque accuracy.

Key Facts

High-volume trailer assembly across multiple facilities
Manual torque process with significant ergonomic strain
Injury cost exposure of $40,000–$60,000 per incident
Rapid adoption of powered torque solution

Manual torque processes were creating safety risks, fatigue, and inconsistent results

At a high-volume trailer assembly facility in Missouri, operators were responsible for applying final wheel lug torque using large manual click wrenches.

This approach created several operational and safety challenges:

Excessive physical strain on shoulders and backs during repeated torque applications
Slip-and-fall risk if the wrench disengaged under load
Operator fatigue accumulating over long shifts
Inconsistent torque application due to manual variability
No digital traceability or torque verification

These issues increased the likelihood of soft-tissue injuries—costing between $40,000 and $60,000 per incident—while also affecting throughput and overall assembly quality.

A powered torque solution improved ergonomics while enabling data-driven quality control

To address these challenges, the team implemented a solution centered on Ingersoll Rand QXM pistol-grip torque multipliers.

Solution Components

QXM torque multipliers for controlled, power-assisted torque application
QCXD controllers to capture and store torque data
Ergonomic tool design to reduce operator strain

Why this solution fit the application

Reduced physical effort compared to manual click wrenches
Improved safety through controlled torque delivery
Faster operation for higher throughput
Built-in capability for digital torque validation and traceability

Deployment Approach

Initial pilot conducted at a single facility
Hands-on operator evaluation and feedback loop
Minimal training required due to intuitive design
Rapid transition with no disruption to production

The simplicity and ergonomic benefits of the solution drove immediate operator acceptance and a smooth rollout.

“This solution improved safety, quality, and output all at once, which made it an easy decision to expand to other facilities.”

— Manufacturing Management

technician holding a qxm torque controlled tool

The new process reduced injury risk, improved throughput, and increased consistency

Quantitative Results

Reduced exposure to injury-related costs of $40,000–$60,000 per incident
Faster final torque process, increasing overall throughput
Improved consistency in torque application

Qualitative Results

Operators reported no shoulder or back strain, even during full shifts
Reduced fatigue led to more stable, sustained productivity
Increased confidence in assembly quality
Strengthened workplace safety culture

Scalability Impact

Successful pilot led to expansion across additional facilities
Six additional QXM systems deployed in Midwest locations

QXM Pistol-Grip Torque Multiplier

Ergonomic, power-assisted torque tool designed for high-torque applications.

QCXD Controller

Enables torque verification, data capture, and process traceability for quality assurance.

“The difference was immediate. Operators no longer felt shoulder or back strain, even late in the shift, and the final torque process was faster and safer.”

— Manufacturing Engineer

technician holding QXM torque multiplier

Does this challenge resonate with your business?

Connect with a Specialist

Take the next step toward safer, more efficient torque processes. If your team is still relying on manual torque tools, upgrading to a powered, data-enabled solution can deliver immediate improvements.

Transportation Manufacturing Case