Case Study
Automated Screwdriving Station Upgrade
End‑to‑end retrofit of a screwdriving station — toolchain upgrade, PLC logic, digital confirmations and full traceability powered by the InduX Backbone.
Goal
Increase stability and reduce NOK caused by torque deviations, while improving cycle time and ensuring consistent operator guidance.
Challenge
Legacy screwdriver toolchain, no digital confirmations, variable operator skill, missing per‑screw genealogy, and limited PLC I/O budget.
Our Approach
Step 1 — Project Management & Planning
Requirements, risks, FAT plan and torque validation method; structured timeline with clear milestones.
Step 2 — Mechanical & Tooling Upgrade
Screwdriver, bit management, fixture improvements and ergonomics.
Step 3 — PLC & Safety Integration
Cycle logic, interlocks, tool enable, NOK handling and alarms.
Step 4 — Digital Execution & Control (InduX)
Order-driven steps, operator guidance, tool OK/NOK, confirmations, data commit.
Step 5 — Traceability & Reporting
Torque/angle per screw stored with order & station context; searchable genealogy.
- PLC: Rockwell (I/O budget optimized)
- Tool: Electric screwdriver with torque/angle feedback
- HMI: InduX UI for operator guidance & confirmations
- Data: InduX Backbone (orders, results, genealogy)m
- Connectivity: ERP/MES handshakes where applicable
- Safety: Interlocks, E‑stops, NOK management
−25% torque deviations
Reduction of NOK related to over/under‑torque events.
+12% throughput
Cycle time improvement with guided steps and interlocks.
100% traceability
Per‑screw torque/angle stored with order & station context.