Tightening Control in Assembly Case Study

This case study details the implementation of a new tightening control solution, Smart Assembly Management System (Smart AMS), by an automotive manufacturer. The previous IT system, which was self-made and linked to a PLC-based tool control, resulted in high maintenance costs and low flexibility in production. The new system centralizes tightening data management and eliminates the need for an industrial PC at each assembly station, leading to significant cost savings. The transition to Smart AMS reduced configuration change costs from EUR 1,500 to approximately EUR 90, yielding savings of about EUR 1,400 per change. Additionally, the first-time-right (FTR) rate improved from 71% to 97%, significantly enhancing production quality. The annual rework effort was reduced from EUR 5.8 million to EUR 600,000, resulting in total savings of EUR 5.2 million. The study concludes with plans for further enhancements, including operator guidance for complex assembly processes.