How to Improve Efficiency in Production Lines Using Torque Arms and Screw Feeders 

Streamlining small parts assembly is an ongoing quest for manufacturers seeking every competitive edge when margins tighten. Shaving seconds or simplifying repetitive actions across production translates into tangible savings that flow straight to bottom lines. That’s why integrating advanced auxiliary equipment like torque arms and automated screw feeding systems should be a priority for engineering leaders striving for lean, nimble factories.

This guide explores the efficiency deficiencies plaguing many conventional assembly lines and demonstrates how purpose-built torque-assist arms and intelligently designed screw presenters transform outcomes. Let’s uncover why upgrading both human and hardware factors pays real dividends.

The Challenge of Manual Fastening 

Consider the cumulative strain of manually driving hundreds of fiddly screws per station, per shift in factories lacking ergonomic supports. It’s a recipe for fatigue, poor technique, and injuries that diminish quality and output over time. Yet many managers tolerate makeshift methods that compel assemblers to:

•  Constantly bend down to pick up screws from bins. This contortion causes back pain and wasted motion.
• Grip/aim screws manually for insertion while also trying to start/drive them squarely. Misalignment risks damaging parts/fasteners. 
• Hunch over workpieces at awkward angles to access confined spaces which strains wrists and shoulders long-term. 
• Hand-drive screws extensively with basic manual screwdrivers adding major exertion. This is tiring and lowers hourly production rates.

Such repetitive strain environments breed inefficiency by forcing assemblers to focus concentration on supporting parts/bodies rather than systematic fastening. It’s an ergonomic formula few workers can sustain unscathed across months or years. 

Relieving Strain with Torque Arms

Specialized torque arms reinvent this manual reality by integrating mechanical assistance at critical stress points. Counterbalanced armatures hovering over work zones eliminate hard reaching that strains backs/shoulders while built-in vises securely hold parts. This frees up workers’ hands for skillful fastening using integral screwdrivers.

Torque arms also provide adjustable assistive torque when driving screws—physically removing the intense exertion that tires wrists. Assemblers simply place a finger on the smoothly gliding driver cap and apply gentle directional pressure as internal motors ratchet screws home with programmed torque. Some models even shut off automatically once tightened to spec for hands-free convenience.

This combination of effort-saving vises, positioning flexibility, and torque-enabled power tool integration converts once-exhausting small parts assembly into an easy glide process shaving precious seconds per fastener. Just a single torque arm can slash screw insertion times by 20-30% or more over manual methodswhile preventing strains.

Optimizing Screw Flow With Intelligent Feeders

Yet finding and handling those fiddly fasteners by hand still remains inherently tedious. That’s where intelligent screw sorting and presenting systems come in according to Alex Vesey, Automation Manager at Flexible Assembly Systems. 

“Any small part that must be manually grabbed and positioned is an efficiency drain and contamination risk. But today’s smart vibratory screw feeder bowls solve this by delivering components oriented and ready for use via programmable linear feed tracks.”  

Modern screw feeders continuously sort bulk fasteners into orderly queues accessible right where assemblers need them. This eliminates walking to distant worktables and fumbling with jumbled bins to hunt for the right screws, washers, spacers, standoffs etc. Just set a feeder bowl for the desired hardware size/type and installation is nearly effortless.

Some advanced screw presenter models even allow easy inventory monitoring and automatic replenishment alerts. RFID data input tracks screw usage while vision sensors ensure no fastener jams impede output flow 24/7. It’s high speed parts handling without headaches according to Vesey.  

“When torque arms and smart screw feeders converge as sister technologies, Exhausting manual fastening processes transform into near robotic efficiency while reducing injuries.” 

But to leverage this powerful combo fully, manufacturing teams Should evaluate three core optimizing factors:

Location Optimization

 Station torque arms directly adjacent to screw presenters so parts flow seamlessly to insertion zones without transfer. This close coupling eliminates search/handling steps.

Height Optimization  

Adjust torque arm and feed track levels to allow workers comfortable standing insertion access without any awkard crouching or twisting. This fine tunes ergonomics and prevents musculoskeletal strains.

Process Optimization

Analyze cycle times, cost per screw rates, part profiles/volumes and workflow to calculate ideal torque assist and programmable feeder settings that maximize output while minimizing costs. 

By interconnecting torque arms and intelligent fastener feeding technologies while optimizing physical integration, manufacturers take the fastest path to screwing productivity.

Why Choose Flexible Assembly System?

 Need to turbocharge small parts assembly with high speed screw insertion and expert sorting/feeding support? For over 28 years Flexible Assembly System has led the way helping clients radically improve production quality, accuracy, and efficiency. As specialists in assembly ergonomics and automated parts handling, we offer complete turnkey process analysis, equipment supply, programming optimization and staff training to ready factories for the next level.

Here are 5 reasons to choose Flexible Assembly System as your assembly performance partner:

Single Vendor Assembly Upgrade Convenience 

We supply both the category-leading PosiDrive torque multiplier arms and PosiFeed vibratory screw feeding systems suited for intricate electronics through heavy duty automotive applications. This simplifies procurement and coordination while providing holistic solutions.

Expert Consultative Services

Our specialist team provides detailed production analysis and advice tailored to clients’ specific assembly challenges. We identify ergonomic pitfalls, parts flow limitations, cycle time barriers and provide custom suggestions maximizing productivity.

Future-Proofed Scalability 

Our torque arms, screw feeders, tubes, vision sensors, and parts handling systems integrate emerging technologies like machine learning for smarter upgrading as needs change. This prevents solution obsolescence.

Rapid ROI Realization

Most clients achieve full capital payback for our upgraded assembly platforms in under 10 months followed by years of multiplied profits from heightened manufacturing velocity and precision.

Intuitive Local Support 

With master technicians located near all major US production hubs, Flexible Assembly System delivers hands-on setup programming, maintenance training, and live troubleshooting so clients’ upgraded lines thrive reliably.

To learn more about revamping production around enhanced small parts assembly efficiency, torque manipulation, and automated screw feeding, contact the Flexible Assembly System productivity experts today.