Learn how to optimize fastener use in assembly for better performance, reliability, and sustainability. Discover practical tips and strategies to design for assembly and reduce fastener-related issues.

To further optimise fastener use in assembly, consider integrating smart inventory management. This involves utilising technology to track and manage fastener stocks efficiently, reducing waste and ensuring the right fasteners are available when needed. Adopting a just-in-time inventory system can minimise storage costs and prevent overstocking, while RFID tags and automated reordering systems can streamline supply chain operations. Additionally, selecting universal or multi-purpose fasteners can simplify inventory and reduce the need for a wide variety of fasteners, streamlining the assembly process and minimising downtime.

How can you optimize fastener use in assembly?

Fasteners are essential components of any assembly, but they can also be sources of inefficiency, cost, and waste. How can you optimize fastener use in assembly to achieve better performance, reliability, and sustainability? In this article, you will learn some practical tips and strategies to design for assembly and reduce fastener-related issues.

1 Choose the right fasteners

The first step to optimize fastener use in assembly is to select the most appropriate fasteners for your design requirements and constraints. You should consider factors such as load, vibration, corrosion, temperature, accessibility, aesthetics, and serviceability. You should also compare the advantages and disadvantages of different fastener types, such as screws, bolts, nuts, washers, rivets, pins, clips, and adhesives. For example, screws are easy to install and remove, but they can loosen over time and require pre-drilled holes. Rivets are strong and permanent, but they can damage the materials and require special tools.

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Rajeev Kumar

Team Leader -COE- Mechanical | GE Power | Expert Bulk Material Handling Systems | BIS Panel Member MED 06 | EPC Projects | Cost Boss | Project Planning & Management | Rotating Equipment's | WFGD | Lean | SQDC | RCA|HAZOP
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I do agree with the statement. Selection of fasteners is the first step in designing any bolted connection. Also, the grade of the bolt and MOC of fasteners matter a lot. Special attention must be given in coastal region projects. If the specific treatment is not done on fasteners, they corrode very fast and lose their strength. If the equipment is vibratory in nature, solutions for fasteners should include a positive locking arrangement to avoid loosening of fasteners. What u say?

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2 Minimize the number of fasteners

The second step to optimize fastener use in assembly is to minimize the number of fasteners needed to join the parts. You can do this by simplifying your design, reducing the number of parts, using integral or snap-fit features, or using alternative joining methods. For example, you can use tabs and slots, dovetails, or snap-fits to create self-locating and self-fastening parts that do not require additional fasteners. You can also use welding, soldering, brazing, or gluing to create permanent or semi-permanent bonds that do not require fasteners.

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Rajeev Kumar

Team Leader -COE- Mechanical | GE Power | Expert Bulk Material Handling Systems | BIS Panel Member MED 06 | EPC Projects | Cost Boss | Project Planning & Management | Rotating Equipment's | WFGD | Lean | SQDC | RCA|HAZOP
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There are various ways to reduce the quantity of fasteners. When designing bolted connections, we need to consider their main purpose. If it is to facilitate site assembly, some subassemblies can be made with welded connections at the shop, considering transportation limits. Finally, these subassemblies can be connected with bolted connections. This approach will help in reducing connecting fasteners requirements as well as save erection time at site.... What u say?

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3 Standardize the fasteners

The third step to optimize fastener use in assembly is to standardize the fasteners as much as possible. You can do this by using common sizes, shapes, materials, and finishes for your fasteners, and avoiding unnecessary variations or customizations. This will reduce the inventory, cost, and complexity of your fasteners, and make them easier to handle, store, and install. For example, you can use metric or imperial units consistently, use common head types and drive systems, and use the same material and finish for all your fasteners.

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Rajeev Kumar

Team Leader -COE- Mechanical | GE Power | Expert Bulk Material Handling Systems | BIS Panel Member MED 06 | EPC Projects | Cost Boss | Project Planning & Management | Rotating Equipment's | WFGD | Lean | SQDC | RCA|HAZOP
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I disagreeing with the statement, I find standardization doesn't always optimize fastener quantity. While design aligns, EPC project-level implementation introduces complexities. Shop floor execution is streamlined, but project-level variety creates challenges and potential errors. Consider supplying M16×60 and M16x65; a 5mm difference can lead to installation variations. Using M16x65 instead of M16x60 might pose no initial issue, but in another location, it could fall short by 5mm. My practice involves a meticulous review of fastener schedules, opting for a margin in the next higher size. This exercise significantly reduces variety. During this, check bolting locations; an additional 5 to 10mm usually have no issues.... What u say?

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4 Align the fasteners

The fourth step to optimize fastener use in assembly is to align the fasteners in a logical and consistent way. You can do this by following some basic principles of design for assembly, such as minimizing the number of directions and orientations of the fasteners, grouping the fasteners by function or location, and using symmetrical or modular patterns. This will improve the assembly efficiency, accuracy, and quality, and reduce the assembly time, errors, and rework. For example, you can use parallel or perpendicular alignments, use common centerlines or axes, and use grids or arrays for your fasteners.

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5 Automate the fastening

The fifth step to optimize fastener use in assembly is to automate the fastening process as much as possible. You can do this by using tools, machines, or robots that can perform the fastening tasks faster, more accurately, and more consistently than human operators. You can also use sensors, feedback, or vision systems to monitor and control the fastening process and ensure the quality and reliability of the joints. For example, you can use electric, pneumatic, or hydraulic tools, use screw feeders or dispensers, and use torque or force sensors for your fastening process.

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Dr Syreeta Charles-Cole

Tea Researcher & Co-Founder/Director, The Data of Life CIC & Innœra 🍃| Author of Guardians of One
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To further optimise fastener use in assembly, consider integrating smart inventory management. This involves utilising technology to track and manage fastener stocks efficiently, reducing waste and ensuring the right fasteners are available when needed. Adopting a just-in-time inventory system can minimise storage costs and prevent overstocking, while RFID tags and automated reordering systems can streamline supply chain operations. Additionally, selecting universal or multi-purpose fasteners can simplify inventory and reduce the need for a wide variety of fasteners, streamlining the assembly process and minimising downtime.

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6 Evaluate the fastening

The sixth and final step to optimize fastener use in assembly is to evaluate the fastening performance and sustainability. You can do this by testing, inspecting, or analyzing the fastening joints and their effects on the assembly function, reliability, and durability. You can also measure and improve the environmental, social, and economic impacts of the fastening process and its waste, energy, and resource consumption. For example, you can use destructive or non-destructive testing, use quality control or assurance methods, and use life cycle assessment or costing for your fastening evaluation.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you optimize fastener use in assembly?

1

2

3

4

5

6

7

1 Choose the right fasteners

2 Minimize the number of fasteners

3 Standardize the fasteners

4 Align the fasteners

5 Automate the fastening

6 Evaluate the fastening

7 Here’s what else to consider

Engineering Design

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How can you optimize fastener use in assembly?

1

2

3

4

5

6

7

1 Choose the right fasteners

2 Minimize the number of fasteners

3 Standardize the fasteners

4 Align the fasteners

5 Automate the fastening

6 Evaluate the fastening

7 Here’s what else to consider

Engineering Design

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