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Why do torque errors still happen, even with good digital tools?
Torque errors are one of the most common—and costly—issues in discrete manufacturing. Whether you're building industrial machinery, vehicles, or electronics, a single incorrect torque can lead to rework, customer returns, or worse: safety-critical product failures.
Even if you're using advanced fastening tools from Ingersoll Rand, Mountz, Tohnichi, Cleco, Atlas Copco, and ASG (PICO integrates with all commercially available torque brands), common human mistakes and errors can still happen. Operators miss steps. Torque values drift. And if your quality control process relies on paper travelers or tribal knowledge, you're inviting inconsistency.
But it doesn’t have to be that way.
For this blog, we will focus on ASG's X-PAQ system. The X-PAQ™ SD2500 premium torque and angle-controlled brushless DC electric screwdriver system is ideal for industries with tight tolerances and high traceability requirements. PICO connects the X-PAQ system directly to digital work instructions, enabling real-time validation, guided operator instructions, and full traceability. Together, X-PAQ and PICO deliver an error-proofing solution that’s both powerful and practical—especially for small to mid-sized manufacturers.
➡️ See how easy it is to integrate your ASG X-PAQ torque control system with PICO by taking a self-guided tour:
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Why Fastening Failures Still Happen—Even with Smart Tools
The X-PAQ torque control system is engineered for high performance and accuracy, with programmable torque control, angle monitoring, and real-time feedback. But even the most advanced tool can’t stop an operator from grabbing the wrong bolt, skipping a step, or misreading a paper instruction.
Fastening failures often result from:
- Incorrect torque setting or fastener selection
- Skipped or out-of-sequence steps
- Tool not fully engaged before trigger
- Inconsistent operator training across shifts
And while these may seem like small errors, their impact isn't small:
- Scrapped parts
- Delayed shipments
- Expensive warranty claims
- Damaged customer trust
⏯️ Watch this episode of our 'How to Build Smarter' video series to learn the cost of bad torque:
X-PAQ Torque Control System + PICO = Full Fastening Process Control
PICO doesn’t just log torque values—it gives you active control over the fastening process. Here’s how it works:
Digital Work Instructions
PICO replaces static paper with interactive, step-by-step guidance that adapts in real-time. Operators always know what fastener to use, which torque tool to grab, and when the process is validated.
Real-Time Pass/Fail Validation
The X-PAQ torque control system streams torque and angle data into PICO. If a fastener is under-torqued or over-torqued, the operator sees it immediately and cannot proceed until it’s corrected.
Automatic Traceability
Each fastening event is recorded and linked to the part, operator, shift, and tool for full backwards traceability. No more chasing down paperwork or relying on memory for audits.
Configurable Error-Proofing Rules
Set thresholds, retries, escalation paths, and lockouts. If something goes wrong, the system knows and stops it from going further down the line.
Perfect for Growing Shops with Lean Teams
ASG’s X-PAQ torque control system is ideal for manufacturers who want precision without breaking the bank. Paired with PICO, it becomes even more powerful—bringing enterprise-grade error-proofing to SMBs.
Together, you get:
✅ Faster operator training with guided workflows
✅ Fewer defects and rework
✅ Complete traceability from tool to torque to build
✅ A system that scales as your product mix or team grows
Prevent Fastening Errors With Integrated Torque Verification
For manufacturers pursuing ISO compliance or striving to eliminate recurring torque errors, the X-PAQ torque control system and PICO deliver the accuracy and process control needed to build right the first time.
Ready to eliminate fastening errors?
Book a demo to see how PICO integrates with your ASG X-PAQ torque tool for smarter, simpler error-proofing.
Visit our Device Library to see all 200+ no-code tool & device integrations available in PICO.
