Boeing Saves Hundreds of Thousands by Tightening Torque Standards

In aerospace, precision is non‑negotiable. Minor oversights can cost millions or, worse, lives. From NASA’s 125‑million‑dollar Mars Climate Observer tragedy to a NOAA‑N Prime weather satellite losing 233 million due to bolt mismanagement, the stakes are clear.

At Boeing’s Satellite Development Center (SDC) in El Segundo, a Six Sigma black belt, Vu D. Pham, identified bolt torque as a critical failure point. By introducing a PDA‑based calibration verification system from Mountz Inc., he cut calibration costs by hundreds of thousands in the first year alone, and avoided costly failures and repair work.

Calibration Conundrum

The SDC, the world’s largest satellite manufacturer, houses 200+ satellites at any time. Its rigorous pre‑launch testing subjects satellites to 30–100 RPM spin, up to 50,000 lb of vibration, 165 dB sound, and thermal vacuums ranging from –320 °F to +250 °F. The plant holds 3,500 torque tools, each of which must be calibrated per ANSI/NCSL Z540‑1‑1994 standards, adding significant expense.

Senior calibration engineer William K. Jinbo explained that compliance requires full documentation of each torque event—an onerous task when tools must be shipped out for calibration.

Three‑Phase Improvement

Phase 1: Pham’s team evaluated tools and found that many were out of calibration by as much as 1.5× or 2×, despite third‑party checks. Operator variability and inconsistent click‑verification further compromised reliability.

Phase 2: They partnered with Mountz Inc. to develop a portable, PDA‑based calibration system that could be used on the shop floor, eliminating the need to send tools out for yearly calibration.

Phase 3: The new system recorded calibration data and torque values in real time, providing audit‑ready evidence and enabling inspectors to verify tools on‑site. This shift replaced thousands of tool shipments with just five calibration‑only items.

• 12 Mountz Wizard PLUS PDA handheld torque displays/calibration systems
• 27 Mountz BMX torque sensors
• Various Mountz specialty cam‑over and break‑over wrenches and screwdrivers

Jinbo noted initial skepticism, but the system’s accuracy and ease of use earned praise from technicians and boosted confidence in torque application.

Since moving calibration in house, Pham has advanced to new projects, emphasizing that repeatability, reproducibility, and continuous improvement are essential for engineering excellence.

About Mountz Inc.

San Jose‑based Mountz Inc. supplies torque tools—analyzers, testers, sensors, wrenches, and more. Learn more at www.etorque.com.