Fluid Dispensers Reduce Hand Fatigue Replacing cumbersome squeeze bottles with air-powered fluid dispensers has helped a leading manufacturer of OEM and aftermarket automotive components eliminate the risk of hand and wrist fatigue problems on their Midwestern assembly line. Operators at Federal-Mogul Corporation's Logansport, IN, facility produce over 250 different styles of electrical and mechanical fuel pumps that are used in cars, trucks, and farm and construction vehicles. During the assembly process, various tubular fittings are inserted through stamped steel housings, after which beads of copper brazing paste are applied around the joints and reflowed to ensure strong, leakproof bonds. Hand Fatigue Concerns Brazing paste is a heavy, particle-filled material that is similar in texture to wet sand. Like their counterparts at many other companies, operators at Federal-Mogul applied the thick fluid manually, using plastic squeeze bottles. To help prevent operator fatigue, the company instituted a rotation policy that restricted operators to pasting no more than two hours a day. Federal-Mogul's long-term goal, however, was to find a permanent solution that would make the process easier on their personnel. For some time, the brazing department's process engineer had experimented with various application methods, including different bottle styles and pneumatic dispensing guns, but was not satisfied with the results. Finally, a coworker passed along a catalog from EFD (East Providence, RI), a manufacturer of precision dispensing systems. Within a few days, the engineer had arranged an on-site visit from one of the company's product specialists. Automatic Dispensers Provide Long-term Solution After reviewing the application and discussing Federal-Mogul's objectives, EFD's representative recommended a compact, automatic dispenser that uses controlled air pressure instead of hand pressure to apply material. During the demonstration, the specialist filled a 55cc barrel reservoir with brazing paste and attached a stainless steel tip. Next, the barrel was connected to the dispensing unit with a lightweight air hose that permits the operator to move freely around the workpiece. Once the dispenser was connected to the plant air supply, its 0-100 psi air regulator was set at a level sufficient to push the paste from the barrel at a steady, controlled rate. Holding the barrel comfortably like a pen, the specialist placed the tip in position and pressed the electric foot pedal to produce a neat, consistent bead that stopped instantly when the pedal was released. Impressed by the dispenser's ease of use and the lack of repetitive hand movements, the engineer ordered one for more rigorous testing on the shop floor. When the operators who had tried the evaluation unit began asking to use it on a regular basis, the company knew they had finally found their solution. More dispensers followed, and soon Federal-Mogul had six units in constant operation. The company is extremely pleased with the results of their new dispensing method, which they feel has greatly reduced the potential for hand fatigue and repetitive stress injuries. More Benefits Than Expected While ergonomic concerns prompted the switch from squeeze bottles to automatic dispensers, several other benefits appeared once the new equipment was integrated into the daily production flow. Waste has been reduced 60%. The squeeze bottles were not air-tight, and oozed constantly. As a result, the paste often dried out and had to be discarded. In contrast, a whole shift's worth of the new barrel reservoirs can be loaded in advance, then sealed with airtight caps that keep the paste fresh and ready for use. Production is more efficient. Squeeze bottles also required frequent, time-consuming trips to the refilling station. The dispensers, however, are much more efficient -- the operator simply attaches a prefilled barrel to the adapter and starts applying paste. When the barrel is empty, it is removed and a new one is installed--a process that takes seconds, instead of minutes. Training new personnel is much easier. It used to be difficult for new operators to control the flow of paste while trying to get it in just the right place, according to the engineer. "With a dispenser, we can teach a new person how to start and stop the flow in just a couple of minutes, then focus on proper application and our many different product configurations." The best indicator of the new method's success, however, is how well it has been accepted by the operators themselves. "The dispensers make paste application so easy that many people actually enjoy doing it," the engineer concludes. "In fact, pasting has become the brazing department's most requested assignment." -------------------------------------------------------------------------------- To learn how EFD equipment can help you improve your dispensing processes, please e-mail info@efd-inc.com, or in the USA call our Fluid Application Specialists at 800-556-3484.