Requesting a discussion about fixturing for small plastic parts in medium production

I make three parts for one project and the customer is talking about more runs in larger numbers. I'm using the smallest of three parts as the extreme example, but the other two have their own challenges and aren't a whole lot larger. The goal is to lessen handling time of both changing parts over every cycle, and changing soft jaws between ops 1&2 and 3&4. The example part starts as .250" x .250" x 1.150" Ultem 1000, and here it is (Most tolerances are ±.002" --- yes they are that tight for a reason!):



Because this job went from prototyping it and slowly worked up in to the numbers we're dealing with now (2000 pcs over 4 months, not huge, but not tiny when the PO is for 3 different part numbers), I'm doing things probably the worst way possible right now; Two vices, two parts per vice, two ops per cycle. This is what I'm doing now:

Op 1, Talon Grip jaws:


Aluminum spacer / support installed before op 1 vice is loosened:


Op 2 (moving jaw hidden):


Op 3 (and op 4 is basically the same as op 3):


Right now the cycle time is fine, but I would like to reduce the change over time by going to high density fixtures (of which I have made several for other parts). This, and having two fixtures would allow the operator to change parts over quickly AND have time to load the fixtures carefully and not feel rushed. We are making good parts right now, but the few scrap parts that do happen can mostly be attributed to operators misloading parts.

My first thought was to buy 6 double station 4" vices (all I can fit on the table) and have 12 parts come out every cycle (remember ops 1&2 run together, and 3&4 run together). That's going to run me somewhere around $10,000 (not including soft jaw material and labor) and only amortize tool change time (which isn't much), but not help operator change over time at all.

My second thought, and the reason for this post, is to look in to pneumatic clamping on large fixture plates. This is something I've never done and only have a basic understanding of pneumatics. The biggest challenge with this part in particular is that for ops 3&4, the operator closes the vice by sort of 'flopping' the wrench over on the vice screw and nothing more. So the vice is essentially just barely touching the part. Any tighter than that and the part squeezes out. It's a very delicate operation for sure.

Would pneumatics even be remotely appropriate for this application? Would they be able to be regulated down to the tiny forces I need, but still be consistent?

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