HOW A BLIND RIVET SOLUTION HELPED STREAMLINE PRODUCTION AND REDUCE ASSEMBLY-LINE FIREFIGHTING
Challenge
During a Voice of Customer discussion, a high-volume OEM shared concerns around an assembly process that was creating daily operational inefficiencies on the production floor. The existing screw, nut, and washer setup required a two-handed assembly process with small components that were difficult to handle consistently.
Operators frequently dropped or misplaced hardware, slowing throughput and forcing the team into constant reactive troubleshooting to keep production moving. The customer was also experiencing occasional joint loosening caused by inconsistent torque during assembly, creating additional quality concerns and rework risk.
Solution
Field reviewed the application on-site to better understand the assembly challenges and identify opportunities to simplify the process and reduce production disruptions.
After evaluating the application, the team recommended replacing the existing screw, nut, and washer combination with a blind rivet solution. Field then partnered closely with the customer to validate the new design and ensure a smooth implementation with minimal interruption to production.
Results
The updated rivet design transformed the assembly process from a two-handed operation into a streamlined one-handed installation, improving consistency and significantly reducing assembly time.
The new solution also eliminated torque variation issues tied to the previous fastener setup, helping reduce quality concerns and minimizing the risk of downstream production issues.
By simplifying the process, the customer was able to reduce assembly-related firefighting on the production floor and improve overall operational efficiency.
Original assembly time: 17 Seconds
New rivet assembly time: 4.5 seconds
Customer assembles approximately 3,600 per day
Estimated annual labor savings: 2,500 hours
TOTAL SAVINGS: $133,274
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