CASE 01 Automated Shim Selection Machine
Valve-clearance shim selection, re-engineered from a two-pass torque-and-recheck cycle into a single-pass machine decision.
- The Challenge
- Fully manual cycle: assemble a trial shim, torque all 8 cam-cover bolts, gauge every valve for clearance, unscrew, recalculate, reassemble the final shim.
- Every cover was torqued and de-torqued twice per engine — burning cycle time and risking inconsistent bolt torque on rework.
- The PAIR Solution
- Part is assembled once with master shims — no cam-cover bolts needed at this stage — then loaded onto the Shim Selection Machine.
- The machine cycles automatically and calculates the exact shim required; the master shim is swapped for the correct one and the cover is torqued a single time.
2× → 1×
Torque cycles eliminated per unit — no more assemble‑measure‑disassemble‑reassemble loop.