August 2023 Metrology News Magazine

Editors Message:

Recently, after returning from a long-haul flight, I found myself facing the familiar task of responding to a customer satisfaction survey received via email. This survey was replete with a multitude of questions that required predefined numeric answers. As I engaged with the questionnaire, I couldn’t help but ponder the efficacy of this 30,000 feet approach, and left me wondering about the tangible benefits it could offer, in terms of business management or the implementation of corrective measures, aimed at enhancing the consistency and quality of the products and services provided.

Another recent instance of the customer satisfaction survey was after my vehicle underwent a critical safety recall. Just a few hours after collecting the vehicle I found myself facing an emailed customer satisfaction survey. Almost in parallel with receiving the survey I received an email, from the dealer service coordinator, urging me to directly communicate any concerns to him instead of expressing negative feedback through the provided questionnaire (sound familiar?). This prompts the question: “What exactly do senior executives aspire to glean from these surveys, apart from, scoring for their potential financial bonus metrics, and a superficial sense of customer satisfaction”?

In the realm of metrology, it is widely recognized that precise and highly specific targeted data constitutes the sole means by which accurate and confident corrective measures can be undertaken to enhance product quality. Within the context of contemporary manufacturing, the timeliness of corrective actions is profoundly affected by data latency. This is precisely why the integration of measurement processes and closed-loop feedback mechanisms, bolstered by adaptive control systems, is emerging as the prevailing trend.

Over the years, the manufacturing sector has amassed a wealth of data, yet its predominant shortcoming has been the underutilization of much of this data to drive comprehensive enhancements to operational processes. As we continue to amass and compile increasingly large volumes of data, the potential challenge of data overload looms. It is imperative that the data we gather remains actionable, with a focus on specificity rather than generality. The latter kind of data often necessitates the involvement of data analysts who are skilled at interpreting and contextualizing the analysis.

Ultimately, the outcome of a customer satisfaction survey might reveal a commendable 98% satisfaction rate, but the real significance often lies beneath the surface with the remaining 2%. Investigating and comprehending what led to these less satisfactory responses is a task that demands a deep dive. My perspective is that customer surveys tend to concentrate solely on the positive 98%, potentially neglecting the crucial insights that can be derived from the remaining 2%. In manufacturing we are all about routing out the 2% and understanding their cause with the necessary corrective actions. Airlines and car dealers have a lot to learn!

Despite the holiday period August was remarkably resilient from a news perspective. This months newsletter highlights twenty-four of the published stories – the complete library of August articles can be accessed by clicking here.

As usual I welcome your comments, news and views – my inbox is always open.

Keith Mills – Publishing Editor

Collecting Trustworthy 3D Measurements – The Smart Metrology Approach

Manufacturing companies monitor product quality every day by collecting dimensional measurement data. This data is used to investigate the stability of a manufacturing process, determine the ability of the process to ensure part quality and functionality, and establish indices to quantify the capability of the process to meet dimensional requirements. It’s all part of their continuous improvement process. When introducing a new manufacturing process … read more

End-to-End Quality Inspection Achieved With CT Data Analysis

The all-digital movement is winning over manufacturers seeking more automation, connectivity and reliability from their models and machines. Surveys from the Manufacturing Leadership Council and others show strong investments and results from Manufacturing 4.0 and related digital design and manufacturing initiatives. With a robust digital framework in place comes greater speed, depth, and agility in how product data is created and managed … read more

Measuring Stress and Strain With Highest Level of Detail

The new ZEISS ARAMIS Adjustable 24M sensor combines advanced technology with maximum flexibility. The two 24-megapixel cameras capture even the smallest details of 3D displacements and surface strain – both for point-based and full-field measurements. With its unique combination of high local resolution and image recording rate, the sensor offers precise results for a wide range of inspection tasks and meets sophisticated demands in research and development … read more

Industrial X‑ray Inspection vs Industrial Computed Tomography

Both industrial X‑ray inspection and industrial computed tomography are among the imaging methods used in materials testing. But how do they differ and when should which inspection method be used? In the following article from MicroVista evaluates both processes and their usage. Non-destructive materials testing using X‑rays is used to visualise internal structures of materials such as metals, plastics, ceramics and composites. X‑ray images are two-dimensional … read more

Automating Aerospace Manufacturing Component Inspections

The aerospace manufacturing industry is known for its stringent quality requirements and precise manufacturing needs. This industry demands rapid, accurate data collection to produce components that meet the highest safety standards. Automating these processes is a task that has long been on the industry’s horizon, and with API Dynamic 9D Laser Radar, this future is now a reality with the groundbreaking metrology tool … read more

Process Monitoring and Control for Machining Operations

High productivity combined with low manufacturing costs and high workpiece quality are essential prerequisites for sustainability, profitability and competitiveness. Especially when the materials involved are difficult to machine, tool lifetimes can vary greatly – which in turn affects product quality. Today, in the age of digitalization, manufacturing is still heavily dependent on the personal know-how of employees who evaluate, adapt and improve processes … read more

Roller Probe Inspects Large-Scale Composite Materials

Waygate Technologies, a world leader in non-destructive testing (NDT) solutions for industrial and energy inspection, has announced the launch of Krautkrämer RotoArray comPAct, a portable roller probe for manual Phased Array (PA) ultrasonic inspection of large-scale composite materials. The new and enhanced technology complements the existing Krautkrämer RotoArray product line for the aviation, space exploration and wind energy industries … read more

Comprehensive 3D Machine Tool Measurement

The manufacture of precision components requires accuracies that even the most modern processing machines cannot reliably deliver. Quality control therefore involves high-precision measurement of the components. This is typically done with coordinate measuring machines in special measuring rooms away from the machine tool. This tactile measurement is cumbersome, slow and possible only in random samples. And what is even worse … read more

Increasing Quality and Reducing Costs

Today’s modern manufacturing machinery can achieve very high degrees of accuracy. Nevertheless, workpieces continue to suffer from undesired deviations in their nominal dimensions and geometries. To limit the resulting quality losses and cost increases, manufacturers and metrologists rely on tolerances. Tolerances define what deviations from the nominal value are acceptable—and when a part is considered “not OK” (NOK) and thus unusable without improvement … read more

Driving Down Critical Inspection Times

In industries such as aircraft engines and automotive, companies need to rapidly establish the quality of components, both during production and during repair and overhaul. Many of these components are highly valuable and complex, often with hundreds of features per part requiring inspection. To date, much of this inspection has been completed manually – a slow and subjective process. A new, automated system for rapid, repeatable, non-contact measurement of features … read more

ScanBox Provides Precise Digitalization and Inspection of Hairpin-Stator Assemblies

CAPTURE 3D, a ZEISS company and a leading provider of innovative 3D digitizing solutions in the U.S., has announced the ZEISS ScanBox for eMotors, an automated 3D scanning solution for the fast and accurate inspection of complete electric motor hairpin-stator assemblies and multiple or individual hairpins. With an integrated ZEISS ATOS Q-EV blue light 3D scanning sensor, the ZEISS ScanBox for eMotors quickly captures high-resolution 3D measurement data … read more

Augmented Reality Software Accurately Projects Visual Aids Onto 3D Objects

3D Infotech has launched Spotlight AR++ 2.4, an Augmented Reality software that improves the process of inspection, re-work, and manual assembly. Using guided projection of 3D color maps and feature based instructions, Spotlight AR++ overlays precise and interactive digital guidance on real-world parts allowing users to improve manufacturing processes. Dynamic Projection using auto-alignment camera detection has been added to project data color maps … read more

Metrology System Drives Precise Automated Flexible Manufacturing

Electric vehicles, autonomous vehicles, and Industry 4.0 are just some of the key trends and technologies that are shaping the automotive industry today. Automation clearly plays a key role in manufacturing, but what are the challenges faced when traditional automated manufacturing is met with modern-day dynamic requirements? INSPHERE’s recently published white paper analyses how automated processes could adapt and evolve with support from new technology … read more

Automated Edge Break Inspection Installed at Aero Engine Manufacturer

4D Technology has installed and commissioned a 4Di InSpec AT automated inspection system at a leading aerospace engine manufacturer’s engineering facility. Aircraft and aerospace engine components may have dozens of critical specifications for chamfers and rounding, for performance and lifetime optimization. These numerous features are time-consuming to measure manually. Difficult-to-access areas must be replicated in order to measure … read more

Manufacturing In The Age of Artificial Intelligence

Despite challenging supply chain situations, manufacturers are making progress toward Industry 4.0. Most understand that artificial intelligence (AI) and improved analytics can lead to better decisions and, thus, business benefits. However, creating the data management structure for success is something many are still learning. Research shows how top-performing companies are making more significant strides than others. In short, they understand, invest in … read more

Laser Tracker Aids Polar Express Locomotive Restoration

In the heart of Michigan, a piece of real-word (and Hollywood) history is being meticulously restored to its former glory. The Pere Marquette 1225, the historic steam locomotive modelled by Warner Bros. and Robert Zemeckis for The Polar Express, is undergoing a significant restoration process, guided by the Steam Railroading Institute and the precision measurement expertise of metrologists at API Services … read more

Marposs Adds OptoCloud Gear To Its Optical Product Range

Marposs is introducing OptoCloud GEAR, the newest member of the Marposs OptoCloud family. With the introduction of this new device, a profilometer-like tool can now be utilized for fast testing of various gears or shafts right on the shop floor and near the production line. As a result, logistic costs will be reduced, and the inspection chain will become shorter. This enables the prompt identification of manufacturing trends and efficient application of corrections … read more

Rotary/Tilt Head Provides Step-Less Alignment of Sensor

Some workpieces, such as thin sheet metal, must not be touched during the measurement process or moved, or are also too large and hea­vy for rotary axes. In such cases, a multisensor capa­ble rotary/tilt head is needed for measurement on both component sides. The Werth WRT rotary/tilt head can handle higher loads than con­ventional rotary heads and therefore suitable for a wide range of measuring sensors … read more

Heavy Equipment Manufacturer Accurately Captures Geometry In Difficult Conditions

Weldco-Beales has been in business since 1945, making it a decades-old enterprise that has been around for the better part of a century. Any organization that wants to survive that long and thrive needs to continuously adhere to a culture of excellence, constantly finding innovative ways to overcome challenges. Weldco-Beales designs and manufactures attachments for different types of heavy machinery providing truck-mounted cranes, excavator booms … read more

Latest ASME Standard Advocates New Method For Defining Motion Control Precision

The publication of the ASME B5.64 standard ‘Methods for the Performance Evaluation of Single Axis Linear Positioning Systems’ recently is seen as a significant step in the redefinition of measurement of precision in motion systems. The ASME standard suggests that when it comes to defining the precision of ultra-precise single axis linear motion systems companies should move away from conventional planar methodologies … read more

Roughness and Contour Measurement System Offers Modular Design

The new Hommel-Etamic W600 series roughness and contour measurement is a robust and flexible inspection system for the metrology lab as well as shop floor production applications. The W612 has a resolution to 1nm with the TKU400 probing system. All Digiscan probe arms utilize a magnetically attached kinematic mounted coupling that enables quick probe system changeover with minimum retooling time due to automatic probe recognition … read more

Alliance For OpenUSD To Drive Open Standards For 3D Content

Pixar, Adobe, Apple, Autodesk, and NVIDIA, together with the Joint Development Foundation (JDF), an affiliate of the Linux Foundation, has announced the Alliance for OpenUSD (AOUSD) to promote the standardization, development, evolution, and growth of Pixar’s Universal Scene Description technology. The alliance seeks to standardize the 3D ecosystem by advancing the capabilities of Open Universal Scene Description technology … read more

AI Powered Visual Inspection Software Provides Real-Time Quality Control

Telit Cinterion, a global enabler of the intelligent edge, has announced deviceWISE AI Visual Inspection, an AI-powered solution that enables automakers, pharmaceuticals, semiconductors, energy and other manufacturers to optimize quality control, productivity, customer satisfaction and profitability. Designed for a wide variety of factory floor use cases, deviceWISE AI Visual Inspection provides the granular, actionable insights that are critical for success … read more

Advanced Software Accelerates High-Speed Automated Robotic Inspection

KaKue GmbH, based in Obersulm, Germany has been providing reliable measurement services with state-of-the-art metrology technology to its customers for over two decades. From standard measurements to complex problem-solving, KaKue’s measurement specialists guarantee solution-oriented order testing in-house and on-site at the customer’s premises. However, they faced challenges with their conventional measurement methods, which were time-consuming … read more

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