Quality August 2011

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Author: Gillian Campbell

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AUGUST 2011, VOLUME 50/NUMBER 8 WWW.QUALITYMAG.COM

TABLE OF

CONTENTS QUALITY MAGAZINE

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AUGUST 2011

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VOLUME 50

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NUMBER 8

DEPARTMENTS 6

FROM THE EDITOR

New Technology Drowns Quality 8

INDUSTRY NEWS

Source: Wilson Hardness

Initial Quality Declines in Vehicle Launches White House Initiatives Address Lack of Skilled Labor Mexico’s Manufacturing Continues to Grow

24

16 FACE OF QUALITY

Five Key Strategies to Enhance Quality Culture

FEATURES 50 YEARS OF QUALITY

24 HISTORY OF HARDNESS TESTING Hardness testing plays an important role in materials testing, quality control and acceptance of components.

18 OTHER DIMENSIONS

Dazzled by the Digits 20 QUALITY 101

Torque Tool Testing: A Primer

QUALITY MEASUREMENT

30 THE ABCS OF IN-LINE GAGING There is no one-size-fits-all for in-line gaging applications.

QUALITY TEST & INSPECTION

36 IMPROVE SURFACE FINISH MEASUREMENT FOR AEROSPACE MANUFACTURING The latest optical methods for measuring surfaces can be quite adept at measuring difficult-to-access surfaces.

22 QUALITY INNOVATIONS

An Industry Demanding More 48 CASE STUDIES

Vision for the Future Take the Heat Out of the Problem 68 QUALITY PRODUCTS

QUALITY SOFTWARE & ANALYSIS

71 CLASSIFIEDS

40 DOCUMENT CONTROL IS A CORNERSTONE OF EFFECTIVE QMS

72 ADVERTISING INDEX

A document control system can have a direct impact on an organization’s ability to serve its customers. They need to choose whether it will be positive or negative.

NEXT MONTH Styli

QUALITY MANAGEMENT

44 SUPPLY CHAIN QUALITY BEGINS WITH YOU Some tips will help get you started on the supply chain quality road.

Environmental Testing GD&T Lean Manufacturing Quality Expo Product Showcase

AUGUST 2011, VOLUME 50/NUMBER 8 WWW.QUALITYMAG.COM

ABOUT THE COVER The latest optical methods for measuring surfaces are sometimes quite adept at measuring difficultto-access surfaces. However, these methods have yet to be widely adopted in the aerospace industry, primarily because they are simply too new. Source: Mahr Federal

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QUALITY | August 2011

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QUALITYMAG.COM

ONLINE TOC VISIT WWW.QUALITYMAG.COM FOR DIGITAL EDITIONS AND WEB EXCLUSIVE CONTENT

Available On-Demand Precise Tracking with Indoor Location Systems Indoor location systems are transforming automotive manufacturing in two key areas: improving error-proofing and line-rebalancing on the production line, and identifying bottlenecks and improving efficiency on offline areas. The Skilled Labor Pool Evolves In an interview with Quality Magazine, manufacturing consulting company Advanced Technology Services’ President Jeff Owens speaks about the culprits behind—and remedies to—manufacturing’s shrinking skilled labor pool. When is a Subgroup Not a Subgroup? In some cases, what looks like a rational subgroup is emphatically not. This article will show how to identify such situations, set up appropriate control charts and calculate the process performance indices correctly.

CAD-Based Inspection Using Contact Measurement Eddy Current Testing: Its Many Benefits and Applications Measurement 101: Essential Knowledge

CONNECT WITH QUALITY: Connect with us to receive updates and to network with other industry professionals just like you.

Industry experts share their views on the latest in quality and manufacturing: • Jim’s Gems: Weekly Updates! • NEW! Shifting the Paradigm

• Quality Remix • NDT: Key to Quality and NDT Round-Up • Learning with Lecky, Vision RoundUp and Perspectives in Vision

Podcasts are easy to listen to directly from your computer or downloaded as an MP3 file.

Videos show you the latest products and technology to improve manufacturing processes.

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NOW PLAYING ON Q-TUBE

The Importance of SPC to Quality Management Systems In a recent interview with Quality

Take a look inside Jay Leno’s Garage Jay uses a Faro 3-D scanner to duplicate a part to restore a 1922 engine.

AS 9100 Revision C -- What You Need To Know Three-Part Interview with Quality Professional of the Year Quality Leadership 100 Companies

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FROM THE EDITOR

NEW TECHNOLOGY

DROWNS QUALITY DO QUALITY AND EASE OF USE GO HAND-IN-HAND?

I

GILLIAN CAMPBELL

f you are to believe the news reports, quality is slipping. According to the J.D. Power and Associates 2011 U.S. Initial Quality Study (IQS), after an improvement in the quality of newly launched models every year from 2007 to 2010, the initial quality of 2011 new model launches has declined considerably. Overall initial quality improves to an average of 107 problems per 100 vehicles (PP100) in 2011 from 109 PP100 in 2010. However, the initial quality of launch models—those that are all-new or have had major redesigns—worsens by 10% to an average of 122 PP100 in 2011 from 111 PP100 in 2010. Conversely, carryover models—those that have had no significant redesign in the past year—have better initial quality than ever before. Owners of these vehicles report an average of just 103 PP100 in 2011, compared with 108 PP100 in 2010. “Exciting models with the latest features are crucial for winning over today’s demanding consumers,” says David Sargent, vice president of global vehicle research at J.D. Power and Associates. “However, automakers must not lose their focus on the importance of these models also achieving exceptional quality levels. Expected reliability continues to be the single most-important reason why new-vehicle buyers choose one model over another, and no manufacturer can afford to give consumers any doubts regarding the quality of their latest products.” The study notes that the decline in vehicle launch quality is evident in a number of areas, including the engine/ transmission and audio/entertainment/navigation categories. The two primary causes for this quality decline: • As automakers are designing engine and transmission software to meet government regulations and make their models as economical as possible, this sometimes leads to the engine or transmission

“hesitating” when accelerating or changing gears. Consumers this year are reporting this as a problem more often than in past years. • Automakers are accelerating the introduction of multimedia technology into their models, including hands-free and voice-activation systems. Many consumers want this technology, which is perceived to enhance convenience and safety, but some vehicle owners report that their system is not intuitive and/ or does not always function properly. It strikes me that the ease of use of an item and its functioning properly are lumped into the same category. A system that is not intuitive doesn’t mean it is of poor quality. To my knowledge, no one I know has ever suffered more than a paper cut reading an owner’s manual. Besides, what is intuitive to me isn't necessarily intuitive to you. I receive myriad press releases every week on new equipment and software that the manufacturer labels as “intuitive” and “user friendly.” Certainly not all of the systems and software can be used right out of the box, but does that mean they are low–quality products? Certainly not. Should ease of use and quality be lumped into the same category? Share your thoughts with me at [email protected], or with other members of the Quality community at the Quality Magazine LinkedIn Group page, the Quality Facebook page and on Twitter at http://twitter.com/QualityMagazine.

Gillian Campbell, Editor [email protected]

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COMING EVENTS AUGUST 21-25 LOOKING TO THE FUTURE NCSL International, National Harbor, MD (303) 440-3339, conference.ncsli.org SEPTEMBER 13-15 MATERIALS TESTING 2011 Telford, United Kingdom British Institute of Non-Destructive Testing www.materialstesting.org 20-22 QUALITY EXPO, Chicago, UBM Canon (310) 445-4200 www.canontradeshows.com/expo/qexpo11 OCTOBER 16-20 MATERIALS SCIENCE & TECHNOLOGY 2011 Columbus, OH, ACerS, (614) 794-5894 www.matscitech.org 24-28 ASNT FALL CONFERENCE AND QUALITY TESTING SHOW, Palm Springs, CA The American Society for Nondestructive Testing (800) 222-2768 www.asnt.org/events/calevents/ calevents.htm

PEOPLE NEWS Applied Manufacturing Technologies (AMT, Orion, MI), a supplier of factory automation design, engineering and process consulting services, has appointed RICHARD SARO to the role of automotive account manager. Saro will support and partner with new and existing customers to develop solutions for the company’s robotic automation customers in the automotive industry. Ford CEO ALAN MULALLY has been named 2011 Chief Executive of the Year by Chief Executive magazine. Peer CEOs voted in this 26th annual contest. The 10 most frequently cited nominations were evaluated and a winner voted on at a meeting of a peer selection committee, which took place earlier this year in New York City. Prior CEO of the Year winners include BILL GATES, JACK WELCH, MICHAEL DELL, A.G. LAFLEY, JOHN CHAMBERS, ANNE MULCAHY, LARRY BOSSIDY, ANDY GROVE and HERB KELLEHER. Mulally’s selection as 2011 CEO of the Year was celebrated at an invitation-only event hosted by NYSE Euronext and the Chief Executive Group at the New York Stock Exchange in July. Pelican Products Inc. (Los Angeles) announced that President and CEO LYNDON FAULKNER has won the 2011 Ernst & Young Entrepreneur of the Year Award in the manufacturing category. The award program recognizes entrepreneurs who demonstrate extraordinary success in the areas of innovation, financial performance and personal commitment to their businesses and communities. Faulkner was selected as a finalist with 21 other nominees by a panel of independent judges.

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BUSINESS NEWS | COMING EVENTS | PEOPLE NEWS | MERGERS

INITIAL QUALITY OF RECENT VEHICLE LAUNCHES DECLINES WESTLAKE VILLAGE, CA—After an improvement in the quality of newly launched models every year from 2007 to 2010, the initial quality of 2011 new model launches has declined considerably, according to the J.D. Power and Associates 2011 U.S. Initial Quality Study (IQS). The study has been conducted annually for the past 25 years. Overall initial quality improves to an average of 107 problems per 100 vehicles (PP100) in 2011 from 109 PP100 in 2010. However, the initial quality of launch models—those that are all-new or have had major redesigns—worsens by 10% to an average of 122 PP100 in 2011 from 111 PP100 in 2010. Conversely, carryover models—those that have had no significant redesign in the past year—have better initial quality than ever before. Owners of these vehicles report an average of just 103 PP100 in 2011, compared with 108 PP100 in 2010. Lower PP100 scores indicate a lower rate of problem incidences and therefore higher initial quality. “Exciting models with the latest features are crucial for winning over today’s demanding consumers,” says David Sargent, vice president of global vehicle research at J.D. Power and Associates. “However, automakers must not lose their focus on the importance of these models also achieving exceptional quality levels. Expected reliability continues to be the single-most-important reason why new-vehicle buyers choose one model over another, and no manufacturer can afford to give consumers any doubts regarding the quality of their latest products.” Only seven all-new or redesigned models rank among the top three of their respective award segments, com-

pared with 17 models in 2010, and only one launch model receives a segment award this year vs. five launch models in 2010. Just one-fourth of redesigned models perform better than the outgoing previous-generation model did in 2010, and eight all-new models perform above their respective award segment average. The decline in vehicle launch quality is evident in a number of areas, most notably the engine/transmission and audio/entertainment/navigation categories. There are two primary causes for this quality decline: • With high fuel prices and more stringent government regulations, automakers are designing engine and transmission software to make their models as economical as possible. However, this sometimes leads to the engine or transmission “hesitating” when accelerating or changing gears, and consumers this year are reporting this as a problem more often than in past years. • Automakers also are accelerating the introduction of multimedia technology into their models, including hands-free and voice-activation systems. Many consumers are attracted by this type of technology, which is perceived to enhance convenience and safety, but some vehicle owners report that their system is not intuitive and/ or does not always function properly. “Clearly, consumers are interested in having new technology in their vehicles, but automakers must ensure that the technology is ready for prime time,” says Sargent. “Successful companies will be those that can take this incredibly complex technology and make it reliable, seamless and easy for owners to operate while they are driving. There is an understandable desire to bring these technologies to

View the latest in quality industry news by visiting our headlines at qualitymag.com—updated daily. Just click the tag now and see what you’re missing. If you don’t have the mobile app on your smart phone, visit http://gettag.mobi to get started.

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market quickly, but automakers must be careful to walk before they run.” While overall vehicle quality continues to improve, the introduction of new technology is expected to continue to pose challenges for automakers. Overall problem rates for audio/entertainment/navigation systems in 2011 are 18% higher than in 2010 and 28% higher than in 2009. The Initial Quality Study serves as the industry benchmark for newvehicle quality measured at 90 days of ownership. The study is used extensively by manufacturers worldwide to help them design and build better vehicles and by consumers to help them in their vehicle purchase decisions. Initial quality has been shown throughout the years to be an excellent predictor of long-term durability, which directly impacts consumer purchase decisions. The study captures problems experienced by owners in two distinct categories: design-related problems and defects and malfunctions. Lexus leads the overall nameplate rankings with 73 PP100 on average.

Following in the rankings are Honda (which improves to second rank position in 2011 from sixth in 2010), Acura, Mercedes-Benz and Mazda (which improves to fifth rank position in 2011 from 18th in 2010), respectively. Land Rover posts the largest improvement in 2011, reducing problems by 47 PP100 from 2010. Honda garners seven segment awards for the Accord, Accord Crosstour, Civic (in a tie), Element, Fit, Insight (in a tie) and Ridgeline. Lexus receives four segment awards for the ES, GS, GX and LS models. For a second consecutive year, the Lexus LS has the fewest quality problems in the industry with just 54 PP100. Chevrolet, Ford and Mercedes-Benz receive two awards each. Chevrolet receives awards for the HHR and the Tahoe; Ford for the F-150 and the Taurus; and Mercedes-Benz for the GLKClass and the E-Class cabriolet/coupe. Also receiving segment awards are the Cadillac Escalade; Chrysler Town & Country; Dodge Challenger; and Mazda MX-5 Miata.

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HOW TO MAKE YOUR MACHINE WORK SMARTER Automate my fixture and part set-ups. ✔ Verify the integrity of the tool in the spindle. ✔ ■ Measure and compensate cutter length and diameter at working RPM. ✔ ■ Confirm my machine’s calibration status. ✔ ■ Stop my machine in milliseconds in case of a crash. ✔ ■ Measure critical part dimensions and geometries without moving the part to a CMM. ✔ ■ ■

Only one gaging company can supply a cost-efficient suite of spindle touch probes, laser tool setters, on-machine measurement and verification software, crash sensor, tool, machine and process monitoring technology, then take total responsibility for integrating the components and ensuring your successful application — MARPOSS. You can have confidence that all the pieces of the puzzle will come together. And finger-pointing will be a thing of the past. MARPOSS MAKES SENSE. Visit us at www.marposs.com/MakesSense SEE US AT QUALITY EXPO IN BOOTH #514

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NEWS Among all-new and redesigned models, the Hyundai Equus and Dodge Durango are notably strong performers, each ranking second in their respective segment. The 2011 U.S. Initial Quality Study is based on responses from more than 73,000 purchasers and lessees of new 2011 model-year cars, trucks and multiactivity vehicles surveyed after 90 days of ownership. The study is based on a 228-question battery designed to provide manufacturers with information to facilitate identifying problems and drive product improvement. The study was fielded between February and May 2011.

WHITE HOUSE INITIATIVES ADDRESS LACK OF SKILLED MANUFACTURING LABOR CLEVELAND—The National Tooling and Machining Association (NTMA) and the Precision Metalforming Association (PMA) salute a White House initiative to expand U.S. manufacturing by recruiting and educating more skilled workers. The initiative mirrors ongoing efforts by NTMA, PMA and other manufacturing groups to develop more qualified workers for the metalforming, tooling and machining industries through two main avenues: actively recruiting new workers and developing widely recognized credentials that signal their qualifications. “It is essential to the future of our industry that we find creative ways to attract the attention of new workers,” says NTMA President Dave Tilstone. “That’s why NTMA sponsors activities like the National Robotics League, which draws students to technical careers by partnering student teams with local manufacturers to build complex machines designed to do battle

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and test ingenuity—all while building high-tech skills.” PMA President Bill Gaskin says that alongside creative recruitment efforts, the key to developing more skilled workers in the United States is the use of uniform, widely-recognized and industry-driven credentials to demonstrate competency in the specific industry skills needed by employers. “PMA and NTMA have worked closely with the National Association of Manufacturers to devise a way to validate metalworking industry skills through the National Institute of Metalworking Skills (NIMS) machining and metalforming certifications,” Gaskin notes. “NIMS certifications offer a concrete path for students to acquire or increase specific skills, while in turn providing a set of credentials that signal employers that they’re able to perform to quality standards in a skilled machining or metalworking job. Both the worker and employer benefit as a result.”

MEXICO’S MANUFACTURING CONTINUES TO GROW MEXICO CITY—Manufacturing in Mexico continues to grow in 2011 with both new and existing companies expanding operations across various sectors, most notably record-breaking numbers in auto production and vehicle exports. In May, more than 213,000 cars were manufactured in the country, 19.4% more than in the same period in 2010, representing the highest record, according to Eduardo Solis, president of the Mexican Association of the Automotive Industry (AMIA). In the same month, exports rose 21.3%. May capped a fivemonth growth period for the first part of 2011, increasing 17.1% over 2010 figures and 16.4% over 2008 rates. In

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addition, Mexico, as the ninth-biggest vehicle producer in the world, produced a record 2.261 million vehicles in 2010, up 50% from 2009, according to AMIA. Continuing the trend in increased vehicle production, Mazda announced that it will begin construction of a new plant in Guanajuato, Mexico, this fall, with vehicle production to start in the second half of 2013. The investment of $500 million will allow Mazda to produce at least 50,000 cars a year at the plant. In addition, the Daimler Trucks North America plant in Saltillo, Mexico, is including a third shift, adding 479 more manufacturing workers and 32 additional staff workers. This will help meet demand for Daimler Trucks North America’s its Freightliner and Western Star trucks. Carlos Guzman, ProMexico’s CEO, recently stated that “because of its manufacturing capacity, Mexico is a very competitive platform for several European and Asian economies that are looking to penetrate or increase their participation in the United States. Mexico is a remarkable manufacturing hub for the automotive industry, among others.” Automotive parts supplier Delphi is investing $11 million and generating 2,000 jobs for a new auto parts manufacturing facility in the state of Durango. This will be the first Delphi plant in that state. Additional manufacturing growth is illustrated by Hawker Beechcraft’s continued expansion in Chihuahua City. The company has opened two plants in the city in 2011, with plans to invest $108 million more in opening another new plant, which will create 600 new jobs assembling structural parts for King Air turboprop airplanes. In addition to auto and aircraft production, the steel industry also is

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growing in Mexico. President Felipe Calderon announced in June that Posco, a Korea-based company, is going to expand its steel plant in Altamira, Tamaulipas, with an investment of $300 million. According to the president, this expansion will create 300 direct jobs and more than 600 indirect positions. During the Posco expansion announcement event, Egidio Torre, Tamaulipas Governor, said that this investment shows that there is confidence to invest in the state. With such expansion continuing throughout Mexico, and in light of Mazda’s most recent announcement, Calderon promises that Mexico will continue to work to promote more investment in the automotive, aerospace, electronic and manufacturing sectors. This will continue to strengthen the country’s worldwide reputation and position as an international manufacturing leader.

FORD PLANS TO DOUBLE CHINESE PRESENCE CHONGQING, CHINA—Ford Motor Co.’s passenger car joint venture in

ASSOCIATION NEWS THE AUTOMOTIVE INDUSTRY ACTION GROUP (AIAG, Southfield, MI), a not-for-profit, membersupported organization that works with manufacturing companies and service providers, is partnering with the SAE INTERNATIONAL to launch a joint global sourcing engineering certificate program. The courses will help teach engineers, quality professionals, purchasers and other specialists how to improve efficiencies and cut costs within the global design engineering community. SOCIETY OF MANUFACTURING ENGINEERS (SME, Dearborn, MI) local Chapter 5 in Chicago awarded two college students $2,000 scholarship awards from its Marshall Blu Scholarship Fund. The awards were approved by the board of directors after recommendation by Ken Croswell, scholarship director for SME locally. The award was made to Maria Katzarova of Chicago during a SME sponsored presentation and tour of the Navistar/International Truck Diesel Engine Plant in Melrose Park, IL. Katzarova is attending the Illinois Institute of Technology as a chemical engineering student. The presentation was made by Ken Croswell and Bob Iossi of SME Chapter 5 to Katzarova before the tour. The second award was to Denise Karabowicz of Bartlett, IL, who is attending the University of Southern California. Karabowicz is seeking a degree in mechanical engineering.

China, Ch Changan Ford Mazda AutomoChi F dM d A bile (CFMA), broke ground for a new engine plant in Chongqing. The $500 million investment will more than double CFMA’s annual engine production capacity in China to 750,000 units when it comes online in 2013. These engines will equip Fordbrand vehicles manufactured and sold in the country. The new engine plant represents one of several new investments that Ford has made to support its aggres-

sive Last i expansion i plan l iin China. Chi L July, J l Ford’s commercial vehicle partner in China, Jiangling Motors Corp. (JMC), broke ground for a $300 million vehicle assembly plant in Nanchang. JMC produces the Ford Transit, a leader in China’s light bus segment. In April of this year, Ford announced that it will bring 15 new vehicles to China by 2015. These products will strengthen Ford’s position in existing segments while driving new growth in others. In addition, Ford

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signed a memorandum of understanding in May to build its first transmission plant in the country, also in Chongqing, with an initial annual capacity of up to 400,000 units. Early next year, Ford’s second passengercar assembly plant in Chongqing will begin production, starting with the new Ford Focus. Ford plans to double the number of employees and dealership outlets it has in China by mid-decade.

MANUFACTURING CONFIDENCE IN U.S. ECONOMY DROPS CHICAGO–U.S. manufacturing leaders have turned pessimistic regarding the U.S. economy, according to Grant Thornton LLP’s most recent Business Optimism Index, a quarterly survey of U.S. manufacturing business leaders. Only 40% believe the U.S. economy will improve in the next six months, down from 60% three months earlier. At the same time, 26% believe the U.S. economy will get worse, up from 3%. “There are many factors causing concern amongst U.S. manufacturing leaders,” says Wally Gruenes, manufacturing practice leader at Grant Thornton LLP. “Soaring energy and raw material costs and Japanese manufacturing supply chain disruptions are weighing heavily, as are unresolved U.S. debt reduction issues and a corporate tax rate that still puts the United States at a global competitive disadvantage.”

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SANTA MONICA, CA—Sales of hybrid and plug-in electric vehicles fell to a 16-month low in May, dragged down by real and imagined supply constraints and increased competition from lowerpriced gas-powered small cars, reports Edmunds’ AutoObserver.com. May sales of hybrid and electric-drive vehicles were off 35.8% from a year earlier, lead by dramatic declines in sales of Toyota and Honda models. Overall, Toyota and Lexus hybrids dropped 45.1% for the month. Honda, the second-largest producer of hybrids, saw its sales in the segment fall 29% in May. “For those selling hybrids, it is incredibly bad luck that the Japanese earthquake and associated production disruptions occurred as gas prices were reaching their highest levels in three

years,” says Edmunds.com Chief Economist Lacey Plache. “While Japanese automakers may well gain back their lost share on other vehicles, hybrids will face an even steeper climb back to previous levels, given the greater and growing competition from fuelefficient, nonhybrid vehicles.” Leading the slump was the decline in Toyota Prius sales, which traditionally accounts for about half of the hybrid market. A total of 6,924 Priuses were sold in May, down 51% from the same month last year. Low supply and higher prices have made the popular hybrid less palatable to consumers. A pricing analysis by Edmunds.com found that the effective cost of a new Prius was $2,500 more in May than just three months ago.

NEW ANALYSIS ON BEST PLACES FOR MANUFACTURERS GREAT BARRINGTON, MA—Despite the conventional wisdom that the South is best place for manufacturing in the United States, eight of the top 10 states for cost-efficient manufacturing are located in the West and Northeast, according to new research by the American Institute for Economic Research (AIER). The research is discussed in the new AIER Economic Bulletin “Competitiveness and Business Costs.” AIER Research Fellow Lei Chen, Ph.D., says the “findings explain why manufacturing firms still may want to consider locating their businesses in the Northeast and on the West coast.” Using 2007 economic census data and a completely data-driven analysis method known as data envelopment analysis, Chen found that the most cost-efficient manufacturing took place in Oregon, Connecticut, Iowa, North Carolina, New York, Arizona, Massachusetts, Nevada, Colorado and Washington. His analysis examined, from an efficiency perspective, inputs including production labor, non-production labor, capital, energy and materials. The 10 states with the least cost-efficient manufacturing, his analysis showed, were Mississippi, North Dakota, Kentucky, Vermont, Alabama, Louisiana, Alaska, Montana, South Carolina and Idaho. “States that are the most costefficient have manufacturing bases that allocate their resources in such a way that relatively low cost inputs replace high cost ones and inputs are used in

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BUSINESS NEWS PRODUCTIVITY QUALITY INC. (PQI, Plymouth, MN) and GDO PRECISION TECHNOLOGY (Norwood, NJ) have signed an agreement that names PQI as importer and exclusive North American distributor of GDO’s Nuremberg Stent Inspection-7 system. The NSI-7 system is the result of three years of research and development in close collaboration with stent manufacturers. Designed for 100% stent inspection, the modular NSI-7 performs geometry measurement of stent structure, 3-D inspection of both inner and outer surfaces, and noncontact wall thickness measurement. NSF INTERNATIONAL STRATEGIC REGISTRATIONS LTD. (Ann Arbor, MI), a management systems registration company, has acquired accredited registration company AQA INTERNATIONAL LLC (Columbia, SC) and AQA’s current international operations. As a result, NSF-ISR and AQA-certified companies will benefit from a wider global footprint in China, Korea, India, Turkey and Malaysia; a larger North American presence and a broader array of service offerings. SIKORSKY AIRCRAFT CORP. (Stratford, CT) announced the completion of the first UH-60M Black Hawk helicopter cockpit produced in the Czech Republic by AERO VODOCHODY, a longtime Sikorsky supplier that has manufactured more than 300 S-76 commercial helicopter airframes since 2000. Sikorsky awarded Aero Vodochody a contract in January 2010 to begin producing the cockpits as a second source for the newest Black Hawk model. Sikorsky is a subsidiary of UNITED TECHNOLOGIES CORP.

the most productive manner,” says Chen. “If all manufacturers allocated their resources this way, on average, U.S. manufacturers could reduce their total production costs by 15.6 % and still produce the same quantities of output.” Chen’s findings are consistent with those of an earlier study, also revealed in AIER’s Economic Bulletin. The earlier study, which Chen participated in while still on the UConn faculty, provides a state-by-state comparison of the production cost per dollar output of manufactured goods—that is, how much it cost to produce one dollar value of goods in different states. That study identified Oregon as the state with the lowest unit production cost per dollar of output. Oregon was followed by North Carolina, Virginia, Arizona and New York. Wyoming, New Mexico, Connecticut, Missouri and South Dakota rounded out the top 10. The bottom 10, the states with the highest unit manufacturing cost per dollar output, included Vermont, New Hampshire, Rhode Island, West Virginia, Idaho, Nebraska, Alaska, Michigan, South Carolina and Kentucky. Arkansas, Louisiana, Mississippi, Tennessee and Alabama—all of which have become popular manufacturing hubs in recent years—all had costs in excess of the national average of 83.3 cents per dollar output.

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LABORATORY TESTING INC. (LTI, Hatfield, PA) continues to expand its line of materials testing services with the recent addition of FOURIER TRANSFORM INFRARED SPECTROSCOPY (FTIR) services. FTIR is an analytical technique used to identify organic, polymeric and in some cases, inorganic materials. LTI is performing the analyses with a hightech Thermo Scientific Nicolet iS10 FT-IR spectrometer. The U.S. Patent Office issued patent number 7,934,428 for the residual torque analysis technology used in ASI DATAMYTE’S (Plymouth, MN) LightStar line of torque and angle wrenches and measurement system. The technology empowers the application of a torque rate differentiation method known as angle restart. This approach was developed specifically to eliminate the false high and false low readings associated with peak measurement and to eliminate the error inducing guesswork associated with the capture angle methodology. DAIMLER TRUCKS NORTH AMERICA (Portland, OR) will hire more than 1,300 new employees at plants in North Carolina, Oregon and Mexico as it ramps up production to meet demand for its Freightliner and Western Star trucks. The new jobs are in addition to the 1,300 positions the company announced earlier this year. Daimler’s truck manufacturing plant in North Carolina will take on a second shift as it adds 535 manufacturing jobs and 37 administrative jobs. The plant in Portland, OR, plans to add 155 manufacturing positions between September and the end of the year. The plant in Saltillo, Mexico, will add a third shift as it hires 479 manufacturing workers and 32 staff workers.

In addition to the top ten, Massachusetts, Pennsylvania, Delaware, Maryland, Colorado, Washington

(state), Indiana, Iowa, Connecticut and Missouri all had costs below the national average.

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FACE OF QUALITY

FIVE KEY STRATEGIES TO ENHANCE

QUALITY CULTURE USE YOUR STRENGTH AND LEADERSHIP TO REMAIN ECONOMICALLY HEALTHY. Editor’s note: This is part two of a two-part series on enhancing quality culture.

O

rganizations should focus on some key quality process areas to meet the demands of the competitive environment and maintain their quality competitiveness.

JIM L. SMITH

1. Develop a new strategic and operational leadership model of quality. It has become increasingly clear that organizations that survive and do well in the markets approach quality as a key part of their strategy. Senior management, in these organizations, has become more hands-on in quality-related activities just as they do in other areas such as finance. This attention provides leadership and a clearly defined role for the quality professional, as well as sending a powerful message across the organization. A key concept that organizations need to adopt is that there is no such thing as a quality problem. When thinking of quality problems, organizations look to the quality manager or the quality department for solutions or where to place the blame. In truth, the problems that exist include: design problems; manufacturing problems; and manufacturing engineering problems. 2. Develop and launch new products which will provide consistent customer value. Faster launches of high quality products rely on strong management leadership, technology and focused quality systems. This integration leads to shorter cycle times with complete quality disciplines to ensure successful product launches delivering consistent customer value performance. For some, this is quite different from the past. While well intentioned and well constructed, some processes were separate islands without bridges to integrate activities with other processes across the organization. In today’s environment, it is imperative that we shift toward more carefully structured, quality-driven activities that pay close attention to customer value practices designed to meet the needs and expectations of the market. Measurement practices need to be in place to ensure the organization is on target and to avoid the backward creep of product quality. 3. Foster a more consistent motivation of human resources to support quality initiatives. This is a departure from the earlier management practice of putting on well-packaged motivational sessions or

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speeches. While often entertaining, these were mostly shallow because when employees went back to work, feeling euphoric, they typically faced ambiguous quality practices and a business as usual atmosphere. Departmental walls remained up which ensured quality improvement remained slow and mostly ineffective in making real change. Today’s environment demands a workplace beyond the worker empowerment of the past. The emphasis needs to be on creating an environment of openness and integrity, of which respect, trust and honesty are cornerstones. This encourages the development of individual quality improvement entrepreneurs. Those best qualified to establish a better way are the ones closest to the actual work. When they are given the ability, tools and support, they also are the ones who can implement the changes. 4. Effective management of suppliers and purchasing activities. In quality-focused organizations this activity is governed by strong, systematic management and emphasis on the quality of suppliers. These organizations focus heavily on better communications within their organizations and strive for a more productive, long-term partnership with its suppliers. This is different than in the past where a “negotiate them down” and combative approach drew battle lines between the entities. 5. Understand the economics of quality. Organizations can do well by fully understanding their total cost of nonquality as it relates to the failure to achieve what Dr. A.V. Feigenbaum called “customer value satisfaction.” I had the opportunity to visit a small company that had a strong quality improvement program focused only on driving down their cost of poor quality. They had everyone involved and accomplished wonderful results through understanding their true cost of failure and their quest to do it right the first time. Organizations have continued to improve, but the lessons have been hard. It’s not only the organizational leadership who needs to change, but the quality professionals and other members of the organization. It is up to us, but remember, you don’t have to do any of these things—survival is not compulsory. Jim L. Smith has more than 45 years of industry experience in operations, engineering, research & development and quality management. You can reach Jim at [email protected].

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DAZZLED BY THE DIGITS METROLOGY KNOWLEDGE WILL OVERCOME DIGITAL BLINDNESS.

T

he digital display has become so much a part of our life, I wonder what the world would do without it. First it was watches. Everyone had to have a digital model even though you can get a faster indication of the time with a fleeting glance at an analog model because you actually have to read and process the numbers on a digital display. What’s in is not necesHILL COX sarily what’s best. Metrology is one of many fields that has felt the impact of digital displays and measuring systems—for better or worse. Anyone can use an instrument and get a reading up on the display. Unfortunately, too many people assume that reading is correct because they’ve never been taught the basics of measurement. It wasn’t that long ago that people worked their way up in a manufacturing company after serving time in various related departments along the way. When they had the opportunity The result to go into the inspection department, they had [of inexperience] is a group a pretty good groundof people who are instrument ing in the basics and an readers but have no idea what appreciation of what a ten-thousandth of an the numbers mean. inch or a micron meant in practical terms. They also had experience in knowing where some manufacturing processes could go off the rails dimensionally, and knew what to look for to prevent such things coming at them out of the blue. That background and training rarely seems to happen much any more. Today, the emphasis is on whether or not the person is computer savvy, rather than skilled or experienced in measurement. The result is a group of people who are instrument readers but have no idea what the numbers mean. In a worst case scenario, they are essentially data collectors, pushing buttons to send data to a software package in a central computer. The result of all of this is a dazzling display of pretty charts and printouts that indicate everything is okay—but sometimes it’s not. We often see examples of digital blindness when customers get a calibration report that indicates something may not be right, but it goes straight into the files so they can prove they had the item calibrated. The piece of paper is more important than what is on it.

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Of course, there are some quality auditors out there who do not suffer from digital blindness and actually look at the reports and understand what the digits mean. And then they start asking those embarrassing questions. In a reversal of this situation, we have folks that question why this year’s report on their gage blocks differs from the one issued last year by a millionth or two here and there. They’re not blind; they see the digits but just don’t know what they mean. In such cases the report is questioned because the blocks have rarely been used and only by a heavenly entity so the changes couldn’t be the result of wear, or so it is claimed. Discussions of measurement uncertainty and block stability will go nowhere. Adding a couple of digits to a digital display is done relatively cheaply and is one of the curses of the technology. Too often the improved resolution is meaningless but it does help to sell instruments, irrespective of how good or bad they are from an accuracy point of view. When you get down to the last digit, metrology knowledge will overcome digital blindness. But getting it is not easy in today’s workplace. This is particularly so when folks believe that massaging numbers with computer programs will keep everything on the straight and narrow. Long forgotten is the old rule, garbage in-garbage out, which means if you don’t know your metrology, you could be loading up an impressive data bank based on dicey measurements. What’s the answer? Training is the obvious answer, but training comes in many forms. For many companies, showing employees how to use the equipment is the gold standard. Unfortunately, this type of training doesn’t answer the “What went wrong?” question when things come unstuck. “I dunno...” will be the usual answer. Someone with some good training will be able to point to a couple of areas, but more likely than not, they’ll sense something not being right before the digits trigger panic stations in the quality department. In the absence of training, the only advice I can offer for everyone involved in the process is never believe the last digit. Hill Cox president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

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QUALITY 101 The upright cylinder shown here is used to apply force to the torque wrench during testing. This design uses vertical cylinders perpendicular to each other (tool grip and round vertical steel bar) to ensure single-point contact during testing. Source: Sturtevant Richmont

TORQUE TOOL TESTING:

A PRIMER Learn the foundation for good torque testing. BY GREG KATSIS

T

orque equals force times distance. This equation sets the foundation for all torque calibration—that of the torque testers as well as the tools. It also sets the starting point for torque testing; the weights (force) and arms (distance) used to calibrate the tester must themselves be certified as accurate to national standards. It is strongly urged that these components be calibrated and certified only by calibration laboratories having ISO 17025 accreditation and an applicable scope. If you test torque tools but send your tester out for calibration, the tester is the foundation of the calibration system. To ensure that the foundation is solid, the calibration laboratory performing the service should have ISO 17025 accreditation for torque tester calibration. The laboratory must have a scope that includes a torque range encompassing that of the tester.

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STANDARDS The ASME B107.300-2010 standard and the ISO 6789 standard supply important information on torque tools and the testers required to test and calibrate them. These standards form an excellent starting point for anyone involved in testing torque tools. FREQUENCY “How often should we test the tools?” is among the most frequently asked questions of every torque tool manufacturer. It also is one of the most frequent sources of misunderstanding and problems. The questioner usually hopes for a simple answer, and the simplest answer is a fixed calendar-based interval. Unfortunately, a fixed calendar interval ignores a host of factors that affect the time when calibration is needed. Is the tool brand new or does it have 300,000 cycles (uses) on it? Is it used to tighten 10 fasteners

each day or 1,200? Is the daily usage rate constant, increasing or decreasing? Is it being used at 40% of capacity or 98%? Are we talking about one type of torque tool or several? Are these all of the same make and model or are there different designs from different manufacturers? These questions apply to each tool individually, and the answer is likely to be different from tool to tool. Applying a simple calendar answer to a population of torque tools invites both interval error types—too frequent and too infrequent calibration. The overly simple approach can even result in the creation of both errors simultaneously. This results in money spent for excessive calibration of some tools while not calibrating others in time to prevent assembly problems. The Calibration Interval Committee of NCSL International faced and addressed this issue some time ago. Their RP-1 (Recommended Practice) publication addressing calibration intervals gives not one, but multiple ways in which a reliable calibration interval can be calculated and maintained through the life of the measurement instrument (the torque tool and the torque tester). Better still, these methods are for the most part easy to understand and cost virtually nothing to implement. The data-driven methods for calibration interval determination effectively adjust for changes in tool (or tester) usage rates, age and wear. The methods in this RP are proven and provide objective answers that reduce the probability of over- and under-calibration. Over time they provide a solid view of the stability (and ownership cost) of each torque tool. This data should be used to make future tool purchases on a more objective basis. EQUIPMENT The advent of the digital torque tester changed the landscape of torque tool calibration. The mechanical torque testers of just a couple of decades ago were cumbersome objects, heavily reliant on the individual to interpolate from

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Current-generation digital torque testers feature exact torque readings of high accuracy, simple push-button operation for easy use and computer communication. Source: Sturtevant Richmont

a dial and to manually record results. Current-generation digital testers are easy to set up and use, require no interpolation and communicate with computers seamlessly. When selecting a torque tester, the accuracy of the tester in relationship to the accuracy of the tools is a primary factor. The tester must be at least four times as accurate as the tools to be tested with it. The ±1% I.V. tester that is acceptable for testing clicker-type torque wrenches is not sufficiently accurate for testing most dial (±3%), flat beam (±2%) or digital (±1%) tools. Further, the tester must support test modes and torque ranges that accommodate the types and capacities of the tools to be tested. Mechanical loaders can be significant assets in ensuring the quality of the test results and the productivity of the technician performing the calibrations. A well-designed mechanical loader will apply force to the tool through a single point of contact, and remain perpendicular to the tool, throughout the arc of movement. Some loaders use a moving arm to achieve these requirements, while others hold the tool in a fixed position and rotate the torque transducer. Either method can work since both can accommodate the fixed distance and perpendicularity requirements. The best designs also will reduce technician fatigue, thus helping maintain technician productivity throughout the day.

Earlier-generation torque testers were reasonably accurate, but were large and cumbersome, usually requiring interpolation to obtain a torque value. Source: Sturtevant Richmont

When a tester and mechanical loader are coupled with purpose-designed software, the calibration process can be made more error-proof and more efficient. Optimal test quality and productivity is attained when the software stores the test protocol, downloads it to and controls the tester during the testing, and uploads each result as it is obtained. Software that also stores the results and outputs a certificate of calibration meeting all requirements on demand will make the process highly cost effective. If power tools are to be tested, additional considerations must be accommodated. Automatic and manual shutoff tools are slightly different in their behaviors, as are electric and pneumatic tools. Additional equipment such as rundown fixtures may be needed to obtain accurate results, and the tester itself must have filters that cover the tool types, brands and designs to be tested. ISO 5393 can be of assistance in determining what is necessary to fill any given set of needs in the testing of power tools. A well-designed mechanical loader will apply force to the tool through a single point of contact, and remain perpendicular to the tool, throughout the arc of movement. It also will ensure that the tool remains perpendicular to the transducer during loading.

See: www.precisionballs.com One week later, he called to discuss the results. His C.M.M. had just been serviced and certified by the machines manufacturer at a cost of $700.00. OUR Ball Bar found that the “Z” axis of this machine was out of square with the “X” axis 0.009” (0.23 mm). The “Z” to “Y” and “X to Y” Axii were perfectly square. After adjusting “Z”-“X” the entire machine was measuring within 0.0003” (0.076mm). He wondered if we had any suggestions on how he might improve this accuracy. As this was an older manual machine, we told him that we thought this was an acceptable accuracy. A simple, inexpensive Ball BarDumbell system provides legal certification according to ANSI B 89.4.1 or VIM-VAR 260

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August 2011 | QUALITY QLT09091baltec.indd 1

21 8/4/09 8:48:14 AM

INNOVATIONS Helix is an innovative and versatile 3-D metrology platform that enables manufacturers to perform challenging measurement tasks. Source: Perceptron

AN INDUSTRY

DEMANDING MORE Intelligent Illumination and Expansive Measurement Volume sets the new Helix apart from other 3-D metrology solutions. BY DARRYL SELAND, EDITOR IN CHIEF

T

with ease and precision. It combines oday’s demanding manufacturing more than 25 years of laser-trianguprocesses push traditional metrollation and 3-D metrology experience ogy solutions to their limit with high with recent technological model mixes, complex advances to create a material combinations and SPECIFICATIONS unique solution for unique short-run parts. » Generates from 1 to 200 the market. In response, Perceptron’s lines on an individual The key benefits to (Plymouth, MI) Industrial inspection point without the Helix system are Business Unit (IBU) has ever moving the sensor. provided through Intelintroduced its ground» Allows for three separate ligent Illumination and breaking Helix 3-D orientations: vertical, horiExpansive Measuremetrology solution. zontal and oblique. ment Volume. Helix is an innovative » Allows for three separate Intelligent Illuminaand versatile 3-D metrolacquisition modes: area, tion is a patent-pending ogy platform that enables line and point. breakthrough that manufacturers to perform allows operators to even their most challeng» Provides a density up to 10 lines per mm. control virtually every ing measurement tasks

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aspect of the sensor’s calibrated light source. By customizing the quantity, density and orientation of the sensor’s laser lines through a simple user interface, image acquisition is optimized on a feature by feature basis. The operator can configure tightly spaced laser lines for small, complex features, increase the number of laser lines to robustly measure challenging materials and alter the orientation of the laser lines to accommodate the differences between multiple parts manufactured on the same assembly line. Prior to Helix, manufacturers were forced to purchase and deploy multiple measurement technologies in order to implement a comprehensive quality strategy. Intelligent Illumination serves as the foundation of a single, in-process solution capable of precisely measuring key dimensional features, as well as generating full 3-D point clouds–allowing, for the first time, a truly integrated, 3-D metrology solution. Harry Rittenour, Perceptron’s president and CEO, states, “Our Helix solution is the most significant development in sensor technology in the past 15 years, and represents a quantum leap in 3-D metrology. Nothing comparable exists in the market today. Helix will provide our customers with a powerful tool for overcoming the challenges they face on a daily basis and a means to successfully implement their most farreaching and innovative strategies for the future.” The benefits of Enhanced Measurement Volume is simple—reduce the amount of hardware and move back to fixed sensors, saving cost and time. Helix sensors use increased measurement volumes, in many cases more than 100 times that of competitive offerings, to effectively and efficiently support those f lexible manufacturing processes. By using Helix solutions, Perceptron’s customers can measure more features on multiple models with fewer sensors, simultaneously adding value and saving money.

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A study of the inspection system of an automotive assembly operation revealed that with the implementation of the Helix 3-D solution the company could reduce its number of camera placements from 22 (right) to six (left) on a back-end inspection. Source: Perceptron

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Rittenour adds, “The significant product differentiators provided by Helix will allow us to deliver a customized, high-precision, affordable solution. A solution that eliminates the compromises customers have had to make with competitive systems. Helix is the embodiment of value innovation—increased capability without added complexity or cost.” For example, a study of the inspection system of an automotive assembly operation revealed that the company could reduce its number of camera placements in its current process— from four to one on a single inspection point, from 22 to six on a back-end inspection and from 125 to 47 on a full-body inspection—by implementing the Helix 3-D system. Over the past several months, Perceptron has installed beta systems at two key customer locations and began taking customer orders. For more information, contact: Perceptron 47827 Halyard Dr. Plymouth, MI 48170 (734) 414-6100 www.perceptron.com

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23

50 YEARS OF QUALITY

History of

Hardness Testing Hardness testing plays an important role in materials testing, quality control and acceptance of components. BY BILL O’NEILL

H

ardness, as applied to most materials, and in particular metals, is a valuable, revealing and commonly employed mechanical test that has been in use in various forms for more than 250 years. Certainly, as a material property, its value and importance cannot be understated. The information from a hardness test can complement and often be used in conjunction with other material verification techniques such as tensile or compression to provide critical performance information. How important and useful is material and hardness testing? Consider the information provided and its significance in structural, aerospace, automotive, quality control, failure analysis and many other forms of manufacturing and industry. Determining these material properties provides valuable insight to the durability, strength, flexibility and capabilities of a variety of component types from raw materials to prepared specimens and finished goods.

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Over the years, various methods for determining the hardness of materials have been developed and employed at varying levels of success. From early forms of scratch testing to sophisticated automated imaging, hardness testing has evolved into an efficient, accurate and valued material test method. SCRATCH TESTING While testing techniques and hardware has significantly improved, particularly in recent years and in step with rapidly advancing electronics, computer, hardware and programming capabilities, earlier, basic forms of hardness testing, such as the simple scratch test, sufficed for the need of the relevant era. Some of the earliest forms of bar scratch testing date back to about 1722. These tests were based on a bar that increased in hardness from end to end. The level at which the material being tested could form a scratch on the bar was a determining factor in the specimens hardness.

Later, in 1822, hardness testing forms were introduced that d th ha included scratching material surfaces with a diamond and measuring the width of the resultant line, a test eventually known as the Mohs scale. In some processes this method is still utilized today. The Mohs scale consists of 10 minerals, ordered from hardest at 10 (diamond) to softest at 1 (talc). Each mineral can scratch those that fall below it in the scale hierarchy. The Mohs scale is not linear; the difference in hardness between 9 and 10 is significantly more than that between 1 and 2. To put the Mohs scale into perspective, a tangible example is that of hardened tool steel which falls at approximately 7 or 8 on the scale. During the next 75 years, other more refined versions of the scratch test were introduced including integrated microscope, stage and diamond apparatuses that applied increasing loads up to 3 grams. The material to be tested was scratched under load variants and then compared to a standard set of scratches of known value. A more sophisticated version of this system employed a diamond mounted at the end of a tapered steel spring.

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Shown is a newer multisample microhardness testing on an automatic stage. Source: Wilson Hardness

The other end of the spring was connected to a balance arm with a 3 gram weight. The material being tested was moved by a hand-actuated wheel and worm gear system, on top of which sat a stage and holding fixture for the material. A fixed pressure was applied as the material was traversed, resulting in a “cut” in the material which was then measured under the microscope with the aid of filar micrometer eyepiece. A mathematical formula, inherent to the process, was then used to derive the hardness. INDENTION TESTS Later, indentation type hardness was introduced. One early form developed about 1859, was based on the load required to produce a 3.5 millimeter indent in the material. The depth was measured with a vernier scale system and the total load needed to reach the 3.5 millimeter was called the hardness. The penetrator consisted of a truncated cone that tapered from 5 millimeter at the top to 1.25 millimeter at the point. This method was mostly effective in soft materials. Another early form of indentation test involved pressing right angles geometries of the same test material into one another and measuring the width of the resulting impression. Various formats evolved from this technique during the early 1900s that likewise used “mutual” indentation of cylindrical test material with the longitudinal axis pressed at right angles to each other. The first widely accepted and standardized indentation-hardness test was proposed by J. A. Brinell in 1900. Brinell’s interest in materials science grew during his involvement in a several Swedish iron companies and his desire to have a consistent and fast means of determining material hardness. The Brinell hardness test, still widely used today, consists of indenting the metal surface with a 1 to 10 millimeter diameter steel or, most recently, a tungsten carbide ball at heavy loads of up to 3,000 kilograms. The resultant impression, the diameter of the indentation, is measured with a low-power microscope after removal of the load. The average of two readings of the diameter of the impression at right angles are made and mathematically calculated to a

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hardness value. The Brinell test essentially introduced the production phase of indentation hardness testing and opened the way for additional indentation tests that were more relevant to material types. Around the same time as the Brinell was developing as a useful test the Scleroscope hardness tester was introduced as one of the first “nonmarking” hardness-testing instruments.

Albert F. Shore, who founded the Shore Instrument Manufacturing Co. in New York, and whose name is now synonymous with durometer testing, engineered the Scleroscope as an alternative hardness test. The Scleroscope used a diamond tipped “hammer,” held within a glassfronted tube that fell, from a height of 10 inches, onto a test specimen. The rebound of the hammer was mea-

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50 YEARS OF QUALITY

Shown, from left to right: a modern day, closed loop Rockwell tester; 16 samples under automatic test utilizing current automation technology; and a modern day fully automated microhardness tester. Source: Wilson Hardness

sured on a graduated scale of Shore units, each divided into 100 parts that provide a comparison with the rebound that might be expected from hardened high-carbon steel. The hard-

The

ness reading is technically a measure of the material’s elasticity. One significant advantage of the Scleroscope was its nondestructive nature in that, unlike the other avail-

Global 8

able methods of hardness testing at the time, a Scleroscope left only a slight mark on the material under test making, presumably leaving it available for use after evaluation.

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MORE EFFICIENT TESTING NEEDS As the 20th century progressed and endured two world wars, with the simultaneous blossoming of the industrial revolution, increased manufacturing requirements and global industrialization brought an urgent demand for more refined and efficient test methods and new techniques began to develop. Accurate, efficient forms of testing were needed in reaction to heavy manufacturing demands, structural failures and the need to design sufficient material integrity into the growing global infrastructure. As an alternative to the Brinell, the Vickers hardness test was developed in 1924 by two gentlemen, Smith and Sandland, at Vickers Ltd., a British engineering conglomerate. The test was designed in reaction to the need to have a more refined test over the material limitations than the Brinell was effective on. The Vickers test uses the same principle as the Brinell, that of a regulated impression on the material, but instead utilized a pyramid shaped diamond rather than the Brinell ball indenter.

This resulted in a more consistent and versatile hardness test. Later, in 1939, an alternative to the Vickers test was introduced by Fredrick Knoop at the U.S. National Bureau of Standards. The Knoop test utilized a shallower, elongated format of the diamond pyramid and was designed for use under lower test forces than the Vickers hardness test, allowing for more accurate testing of brittle or thin materials. Both the Vickers and Knoop tests continue as popular hardness analysis methods today. Although conceived as an idea in 1908 by a Viennese professor, Paul Ludwik, the Rockwell indentation test did not become of commercial importance until around 1914 when brothers Stanley and Hugh Rockwell, working from a manufacturing company in Bristol, CT, expanded on the idea of utilizing a conical diamond indention test based on displacement and applied for a patent for a Rockwell tester design. The principal criterion for this tester was to provide a quick method for determining the effects of heat treatment on steel bearing races.

One of the main strengths of the Rockwell was the small area of indentation needed. It also is much easier to use as readings are direct, without the need for calculations or secondary measurements. The patent application was approved on February 11, 1919, and later, in 1924 an improved design patent was granted. Simultaneously, Stanley Rockwell was starting commercial production of Rockwell testers in collaboration with instrument manufacturer Charles H. Wilson in Hartford, CT. The company grew into the Wilson Mechanical Instrument Co. and became known as the premium producer of Rockwell testers. After some ownership changes through the latter 1900s, Wilson was acquired in 1993 by Instron and today has become an integral part of Instron/ Illinois Tool Works. Now known as Wilson Hardness, the combined expertise of Instron/Wilson, coupled with the subsequent acquisitions of Wolpert Hardness and Reicherter Hardness, have led to the engineering and production of cutting edge hardness systems. The Rockwell test

Look Beyond Compliance. At NSF-ISR, Competitive Performance is Key. ƵƚŽŵŽƟǀĞ DĞĚŝĐĂůĞǀŝĐĞƐ ǆƉĞƌƚĞƌŽƐƉĂĐĞ^ŽůƵƟŽŶƐ ŶǀŝƌŽŶŵĞŶƚ͕,ĞĂůƚŚĂŶĚ^ĂĨĞƚǇ dƌĂŝŶŝŶŐ &ƌĞĞǁĞďŝŶĂƌƐŽīĞƌĞĚƚŚƌŽƵŐŚŽƵƚϮϬϭϭ͘ ŽŶƚĂĐƚƵƐ͊ E^&/ŶƚĞƌŶĂƟŽŶĂů^ƚƌĂƚĞŐŝĐZĞŐŝƐƚƌĂƟŽŶƐ hŶŝƚĞĚ^ƚĂƚĞƐ dŽůů&ƌĞĞ͗ϴϴϴͲE^&ͲϵϬϬϬͮdĞů͗ϳϯϰͲϴϮϳͲϲϴϬϬ ŝŶĨŽƌŵĂƟŽŶΛŶƐĨͲŝƐƌ͘ŽƌŐͮǁǁǁ͘ŶƐĨͲŝƐƌ͘ŽƌŐ ĂŶĂĚĂ dĞů͗ϭͲϮϴϵͲϴϯϴͲϮϮϬϰͮĐĂŶĂĚĂΛŶƐĨͲŝƐƌ͘ŽƌŐ

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50 YEARS OF QUALITY remains as one of the most efficient and widely used hardness test types in use. Hardness testing technology remained fairly consistent throughout the mid to latter 1900s, most systems typically utilizing the dead weight method of applying the test forces. While the deadweight technique is fairly simple, reliable and was widely accepted, the method is not without some ambiguities. Labor-intensive production, coupled with the complexities involved in a highly mechanical system depending on levers, pivots and guides led the need for further development and it became evident that other newly developed forms of force regulation used in measurement instrumentation could be applied to hardness testing as well. CLOSED LOOP SYSTEMS With increasing demands for productivity, accuracy, user features and repeatability, closed-loop, load cell technology became a factor in hardness testing. During the 1950s, Instron pioneered the use of closed loop systems on tensile testing instruments.

Closed loop systems differ from open loop (deadweight) systems in that they have a means to electronically measure the force being applied during every test and feed (or loop) the information back to the control system. The control system is designed to use the feedback to adjust the force application mechanism to apply, at an extremely accurate rate, the desired force. These systems work so well that today all electronic tensile/compression instruments use closed loop control exclusively. With the teaming up of Instron and Wilson, the ability to adapt the closed loop control effectively to hardness testers led to the development of systems with repeatability never before realized. During the early 1990s this technology was introduced first to Rockwell testers, and later to Knoop/Vickers, as well as Brinell systems. Closed loop quickly gained momentum as a means to achieve extremely accurate and repeatable hardness test results. Today the technology is a popular and widely used format. Now, with significant improvements in recent years in hardness testing

instrumentation, computer hardware, electronics, imaging algorithms and software capabilities, the door has opened to extremely precise and reliable testing processes that provide results more quickly than ever before, often in automated fashion. These components and techniques have proven to be beneficial in raising efficiency, speed and accuracy to unparalleled levels. During the past several years, and no doubt increasingly in the future, more traditional manual test processes have and will continue to rapidly give way to automation in every aspect of the testing process. New techniques in material preparation and handling, mount fixturing, stage movement, results interpretation and analysis, and even reporting, have now been introduced to the hardness testing industry. More and more automation technology is being integrated into many hardness systems using stage traversing and image analysis of Knoop, Vickers and Brinell indentations. An automatic hardness system typically consists of a fully controllable tester, including an auto-rotating or

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revolving turret as well as actuation in the Z axis either from the head/indenter housing or from a spindle-driven system used for both applying the indent at a predetermined force as well as for automatically focusing the specimen. Add to this a standard computer with dedicated hardness software, an automatic XY traversing motorized stage and a USB video camera, and the result is a powerful, fully automatic hardness testing system. These systems can be left alone to automatically create, measure and report on an almost unlimited number of indentation traverses. This newer technology eliminates much of the hardware that in the past caused operational challenges and cluttered workspace. Hardness testing plays an important role in materials testing, quality control and acceptance of components. We depend on the data to verify the heat treatment, structural integrity and quality of components to determine if a material has the properties necessary for its intended use. Through the years, establishing means of increasingly more productive

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Shown, from left to right: a legacy Wilson MO microhardness tester, circa 1970; a legacy Wilson “J” Series Rockwell tester, circa 1960s; early version of rebound nondestructive Scleroscope; a deadweight Wilson Rockwell Hardness tester, circa 1960s. Source: Wilson Hardness

and effective testing through refining traditional testing design has given way to new cutting edge methods that perform and interpret hardness tests more effectively than ever before. The result is increased ability and dependence on letting the instrument do the work, contributing to substantial increases in throughput and consistency and continuing to making hardness tests very useful in

industrial and R&D applications and in ensuring that the materials utilized in the things we use every day contribute to a well-engineered, efficient and safe world. Q Bill O’Neill is director, business development and sales at Wilson Hardness, an Instron ITW Co. (Norwood, MA). For more information, e-mail [email protected] or visit www.wilson-hardness.com.


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MEASUREMENT

The ABCs of

In-Line Gaging There is no one-size-fits-all solution for in-line gaging applications. BY MICHAEL BOZINOVSKI

I

typically the same robot or gantry n-line gaging is a hot issue among that loads and unloads the machine quality professionals. But, like most tool, and after being measured the rapidly evolving technologies, the workpiece may be returned for furconcept means different things to difther processing. In this case it is an ferent people. With that in interoperational gage that mind, let’s begin with a TECH TIPS checks specific dimenfew definitions. » An in-line gage is a gage sions and/or geometries For purposes of this that is on the production to verify that the workdiscussion, an in-line gage floor, close to the manupiece is ready for subseis a gage that is on the facturing operations being quent operations. It may production floor, close to performed on a workpiece, also be a final inspection the manufacturing operalocated physically inside gage, used to determine tions being performed the cell, line or other sysif the part meets design on a workpiece, located tem configuration. specifications for its physically inside the » When selecting a gage, it intended use. cell, line or other system is important to begin by It is not an in-process configuration. In most defining exactly what the gage that measures a part applications it is used to gage is expected to do. while it is being machined check 100% of the parts » Evaluate a supplier’s and is interfaced with the being produced and may product line to be sure control to stop the proprovide compensation it includes all of the cessing when the specified feedback to the machine potential gage types and dimension is reached. tools in the process. measuring technologies And, of course, it is It is loaded with that may be suitable for not an off-line gage, an automated device, an application.

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which manually wh whic hich ich iiss m anually loaded and an nd d located locatted d on a gage table, metrology laboratory or other shop floor area away from the manufacturing operations. There are a few other terms that also need to be defined: • A dedicated gage is one that is available in a range of predefined sizes and configurations and is used to inspect a single part type or a very narrow range of parts. • A modular gage is made up of standard components, such as pencil probes, contact arms and work rests mounted on a base that allows mounting details to be randomly located and re-located as necessary to inspect a wider range of parts. • A reconfigurable gage is one with easily changed or repositioned arms, contacts and other features that allow it to accommodate a range of similar parts with little time spent between changeovers. • A flexible gage is one that can inspect a range of part types without having to be reconfigured. Unfortunately, there is no industry agreement of these definitions and,

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This robot-loaded universal gage is one of two interoperational gages used to control quality in an automated cell of vertical turning centers. The multidimensional, modular system can be retooled for measuring internal and external dimensional and geometric checks of cylindrical parts such as bushings, hubs and gear wheels. Data from the gages are used to automatically compensate machine offsets without human intervention. A trending function in the gage amplifier prevents overcompensating the machine tools. Data from the gages also are used by the manufacturer to develop predictive maintenance routines for the cell. Source: Marposs Corp.

therefore, a good bit of ambiguity exists when they are used by various manufacturers and operators. The aforementioned definitions are used by us both internally and externally to differentiate the functionality provided by each category of gage. They are independent both of the particular gaging technology being applied and of the manufacturing processes being monitored. SELECTING THE RIGHT GAGE It is very important to begin by defining exactly what the gage is expected to do. For example, specifying a f lexible off-line gage for an application in which a dedicated in-line gage provides the necessary functionality can add both expense and complexity to the installation, with little or no offsetting benefit.

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The opposite, of course, also would be true. There are a number of questions that have to be answered when selecting an in-line gage, and not all of them are intuitively obvious. Here is a brief checklist of things to consider: • Production rate. Can we measure fast enough to keep up? • Production size. What is the gage cost per part? Can the gage last for life of the production run? • Number of part types. Can one gage measure all parts? • Differences and similarities between part types. Is it better to make some checks on all part types, or all checks on one part type per gage? • Lot size—changeover frequency. Can the gage be manually retoolable or must it be flexible?

• Part material. Can the gage contact the part or must it use air? • Part configuration and size. Are measurements best performed by putting gage in/on the part, or the part in/on the gage? • Measurements needed to control. Do all dimensions need checking? • Part tolerances—geometric, dimensional, surface finish, flaw detection. How precise does the gage need to be? • Checking parts for function or for process control—what datums to use? The machine tool producing the part may not use the same datums that the end product uses. • Process environment—temperature, temperature variation, cleanliness, light conditions. Does the gage need temperature compensation or a washer/dryer? Can inspection be done using visible light?


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MEASUREMENT

The flexible machine uses shadow cast optoelectronic technology for the inspection of a variety of shafts while performing many different types of measurements, without the necessity of retooling and without part contact. It can be integrated into a production line for interoperational or final inspection of parts and can be used as an audit station or for post-process inspection after the machine tool. Source: Marposs Corp.

• Operator skill. Is the gage too complicated? • Process control requirements. Is feedback to the machine tool

This post-process through-feed gage is an automatic system for measurement and inspection of continuously manufactured components. The system is designed to check cylindrical parts on the fly, providing process control feedback to the machine tool. The gage is intended for in-line placement adjacent to material removal equipment such as through-feed centerless grinders, turning centers or other machines. Available measurement technologies include contact-type, pneumatic and noncontact optical sensors. Source: Marposs Corp.

required? If so, how often? • Statistical or data retention requirements. Is a computer needed?

• Location in the process, line or cell layout. Is the gage accessible and convenient? • Ergonomic requirements. Does the gage require difficult or repetitive movements? • Price. Is the price within the budget? • Delivery requirements—timing of the project. Can the gage be delivered in time? • Correlation requirements to another measurement source. Different technologies may give different results. • Part condition—surface finish, temperature, cleanliness, wetness. Does the gage need part temperature compensation, a washer/dryer, noncontact technology? • Automated process or manual. Is automatic part handling needed? • Audit checks or 100% inspection. Are the checks safety related, or only for process control? • Maintenance requirements. Does the operator have the time and skills required to maintain the gage? The answer to each of those questions is important and has a direct bearing on gage type and gaging technology best suited for the particular application. Failing to consider and evaluate all of these points (and perhaps others) will likely lead to a less than optimum solution.

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For example, there often is a tradeoff between time and cost. Using multiple gages to measure a part generally takes longer than doing all the measurements in one gage. The difference may be between performing the inspection in a few seconds or a few minutes. However, a single gage that measures everything in seconds is probably a custom design that may well cost twice as much as two or three simpler gages. The possibility of purchasing components and building your own gage also should be evaluated. Most major suppliers of gaging technology today offer the “pieces and parts” required, and the savings in engineering cost can be substantial. Naturally, in-house design capabilities will be a major factor in this decision. During this phase of the process it also is important to evaluate a supplier’s product line to be sure it includes all of the potential gage types and measuring technologies that may be suitable for the application. It is the only way to be sure that the solutions ultimately offered are the best available and not simply what’s available from a limited product line.

The programmable machine for inspection of families of shafts incorporates two bidirectional measuring heads to provide gaging flexibility at high operating rates. It can statically or dynamically perform many types of dimensional and geometric checks. Due to its low sensitivity to dirt and to part surface roughness, it is designed for use in demanding shop-floor environments immediately after a machining operation. Parts can be loaded into the gage machine either manually or by automation. Source: Marposs Corp.

SELECTING THE RIGHT TECHNOLOGY Finding the right balance between flexibility, accuracy and precision, ease-ofuse and cost is a very important and often difficult task. Different technologies offer a variety of characteristics to help solve this dilemma. Electronic contact-type gages are one of the most widely used categories available today. They are precise, robust, flexible, easy to apply and offer a wide range of measurement. They typically provide a good, economical solution for parts that are likely to be less than perfect when measured because they are able to tolerate contaminants such as coolant, swarf and chips, as well as surfaces that are not extremely smooth due to tooling marks. Air gaging is usually the best inline solution for parts that cannot be touched, and for bores and other details that are too small to accommodate a mechanical gaging probe. While extremely accurate and precise on smooth surfaces, air gaging is an averaging technology so it may not perform

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33

MEASUREMENT

This in-line machine automatically measures 100% of automotive cylinder blocks as part of the production system. In addition to dimensional, geometric and ND checks, the machine can provide functions such as marking, part selection and back-up area. Source: Marposs Corp.

This in-line, post-process gaging system for shaft-type parts incorporates a robot to load parts from a CNC lathe into the gage and from the gage to an off-load area. In the case of a misloaded part, a built-in recoil device allows the gage to collapse, actuating a switch that puts the robot into emergency stop, protecting the gage and tooling. Source: Marposs Corp.

as well as a contact-type gage on rough surfaces. It also can be affected by contamination. Air-type gages also have an added operating expense because they require a constant supply of clean, dry air. Therefore, it is not possible to operate a precision gage on shop air. Air-type gages also are among the most dedicated because they have a very small measurement range. For example,

while this technology can produce excellent results measuring a bore to ±10 microns, it may not be usable at all where the tolerance is ±100 microns. Optical gages can bring a very high f lexibility to the gage solution because of their noncontact characteristic. Optical gages also are often the only solution for particular parts, such as orthopedic joints and other medical devices, which must be perfectly smooth. These gages can detect scratches, blemishes and other surface imperfections that are so minute they can only be seen by the human eye. One rapidly emerging optical technology takes multiple photographs of a surface under white light while the part is moving using a field of view as small as 3 x 3 millimeters for metal parts, or 1 x 1 millimeter for highly polished ceramics. A computer analyzes the images in real-time to provide a 100% surface inspection. While this technology cannot presently provide dimensional data, applications combining it with “shadowcasting” and other optical technologies are under active development.

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THE BOTTOM LINE There is no one-size-fits-all solution for in-line gaging applications. A thorough, methodical evaluation of the application, combined with a realistic analysis of the economics, and an in-depth examination of a potential supplier’s product lines and experience to make sure you will have access to all potentially applicable technologies is the best way to arrive at an optimal solution. Q Michael Bozinovski is a product manager at Marposs Corp. (Auburn Hills, MI). For more information, call (248) 364-4254, e-mail marposs@ us.marposs.com or visit www.marposs.com.

QUALITY ONLINE To learn more about inline inspection, visit www.qualitymag.com to read the following articles: • “Improve Inline Inspection” • “Inline Probing for Process Improvement”

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TEST & INSPECTION

Improve Surface Finish

Measurement for Aerospace Manufacturing

The latest optical methods for measuring surfaces can be quite adept at measuring difficult to access surfaces. BY PAT NUGENT

I

n aerospace production, surface measurement often is used for many components, including high pressure hydraulic systems and fuel injection systems. The surfaces on these components often are narrow and difficult to access, frequently residing in small o-ring grooves or at odd angles on the ends of small, difficult-to-orient parts. A wide variety of probes has been developed to measure these surfaces, but fast, accurate staging of parts—and

36


hence, gaging throughput—remains an issue. At the same time, the need for quality in these components is critical. Seal integrity must be absolute and mating surfaces on connectors must not damage seals. Thus, part tolerances for both form and surface finish on these components are very tight and the need for good measurement process control is rigorous. The latest optical methods for measuring surfaces are sometimes quite

adept at measuring these d difficult-toiffi if ficu fi cullt-t lt-to oaccess surfaces. However, these methods have yet to be widely adopted in the aerospace industry, primarily because they are simply too new. With lives literally on the line and depending on system integrity, engineers are reluctant to risk change, and an “if it ain’t broke, don’t fix it” attitude prevails. Traditional tactile trace methods of measuring surface finish have been validated by many years of compiled data and successful use. To gain similar certitude, optical methods will no doubt have to undergo years of parallel testing to achieve the same confidence level. Nonetheless, there are steps aerospace production engineers can take

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The measurement of surface roughness in bores often is difficult due to the size and depth of the bore. In this example, a dedicated bore fixture, mounted on the front of the handle assembly, accurately positions the probe in the area to be measured. During entry into the bore, the probe is in a protected position. A mechanical device allows the probe to drop into measurement position only when the plug is fully seated against the front of the bore. No operator technique is required for orientation or protection of the measurement probe. Source: Mahr Federal

to improve the speed, accuracy and cost effectiveness of the measuring process while using traditional tactile methods. Consider three such approaches: one in which form and surface measurements are merged on a high end metrology system; a second in which parts are more efficiently staged for measurement on such a system; and a third in which the surface finish gages are customized to allow better access to the difficult to measure features on the parts. All three approaches demonstrate improved ease of use and consequent reduction in operator error, better gage repeatability and improved measurement throughput. MERGING FORM AND SURFACE We have written before (Quality Magazine, September 2006) that, while there are often fundamental differences in the design and manufacture between instruments that measure form and those that measure surface finish, the only real difference between the measurements themselves is the frequency or wavelength of the data set used. In that article we described how measurement data is filtered by wavelength (also known as setting the cutoff in measurement parlance). Within the limitations of a probe or stylus tip and the device used, any part trace includes an amalgam of a nearly infinite number of different wavelengths present in the path being traced. These, in turn, reflect characteristics imposed by the manufacturing process. Traditionally, this data has been divided into three categories: roughness, waviness and form. Shorter wavelength data tends to reflect surface roughness characteristics imposed by machining operations such as turning, grinding or polishing. Waviness involves longer wavelength data and may reflect conditions caused by instabilities in the machining process, such as imbalance in a grinding wheel or worn spindle bearings. Long wavelength data tends to reflect errors such as lack of straightness in the guide-

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There are many applications where it makes more sense to measure parts directly rather than take them into a metrology lab or mount them on a gaging system. There are several rules for the design of such systems. First, in addition to shop-hardening the gage, the design must protect sensitive probe and drive components. Source: Mahr Federal

face finish characteristics according to ways of a machine or misalignment of accepted ISO, ASME and JIS standards machine axes. These long wavelength requires an increase in the resolution errors are usually thought of as form of the typical form measuring instrucharacteristics such as ment and adherence to roundness, straightBENEFITS the filtering requirements ness or flatness. Perfect » Combining form and surface of these standards. straightness, for example, can reduce the number of For tricky aerospace could be described as a required setups and improve components, such sysline, or wave, with an the measurement process, but staging small complex tems offer several benamplitude of zero. parts remains difficult. efits, including reduced Since that article setup and measurement appeared, a number » The ultimate goal is to crecycle time. But measureof manufacturers have ate a solution that requires ments often are easier introduced systems no tools for mounting the part in the fixture and none as well. High-end form which do, in fact, provide for placing the fixture on testers are CNC-based, for the measurement of the machine. meaning they can conboth form and surface trol movement in mulfinish parameters on the » There are many applications where it makes more tiple axes, even several same instrument, often sense to measure parts of them simultaneously. within the same setup. directly wherever they are Thus, a single setup can It should be noted that rather than take them into be used for multiple historically form meaa metrology lab or mount measurements. And surement machines were them on a gaging system. when it comes to meadesigned to measure lonsuring the surface in a ger wavelengths, utilizing small o-ring groove, for example, it is longer spacing (typically 5-10 microns) much easier to accomplish the trace if between data points and some inherthe part is on a rotary table than if it is ent filtering of short wavelength data on a linear gage. within the instrument. Measuring sur-


37

TEST & INSPECTION

A number of manufacturers have introduced systems which provide for the measurement of both form and surface finish parameters on the same instrument, often within the same setup. This model samples data with spacing as tight as 0.005 micron—far exceeding accepted international standards for roughness measurement—and is more robust, less sensitive to environmental influences, faster, more flexible and more accurate for use in production environments. Source: Mahr Federal

KINEMATIC STAGING IMPROVES EFFICIENCY Combining form and surface can reduce the number of required setups and improve the measurement process, but staging small complex parts remains difficult. If you have a plunger about the size of a pen, for example, with a small groove on its side about 1 millimeter across, and it has to be staged in a particular orientation and at a precise angle to run a surface finish trace along the bottom of the groove, the setup is going to require an experienced operator, it is going to take time, and it is going to be prone to measurement error. But the process can be improved. Fixturing systems are routinely designed for companies, which improve the efficiency of staging small complex parts by orders of magnitude. There is no technical wizardry involved, and these systems do not break new conceptual ground. In fact, it is rather the opposite: these systems succeed because they are based on good, solid mechanical design principles and use basic kinematic mounting techniques. The idea is simple. For each part, one or more mounting fixtures is custom designed, depending on the number of features that need to be accessed and measured and the orientations those measurements require. These, in turn,

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Historically, form measurement machines were designed to measure longer wavelengths, utilizing longer spacing (typically 5-10 microns) between data points and some inherent filtering of short wavelength data within the instrument. Measuring surface finish characteristics according to accepted ISO, ASME and JIS standards requires an increase in the resolution of the typical form measuring instrument and adherence to the filtering requirements of these standards. Source: Mahr Federal

mount in another base fixture designed to mount on the measurement machine. The operator simply puts the part in the fixture, puts the fixture in the base, presses the appropriate measurement icon on the touch screen and the system takes the measurement. But while the idea is simple, the implementation requires careful design and planning. In order to be fail-safe, these fixtures must be designed— insofar as it is possible—such that the operator cannot put the part in the fixture wrong and cannot mount the fixture into the base wrong. The ultimate goal is to create a solution that requires no tools for mounting the part in the fixture and none for placing the fixture on the machine. The fixture should be designed in such a way as to ensure that the part is firmly held once it is inserted into the fixture and the holding force is operator independent. Typically this is accomplished with springs to set the holding force. This ensures that the part is always firmly held and the operator cannot forget to tighten some clamping mechanism. Furthermore the clamping force is controlled so that nothing can be over-tightened and distort the part for measurement. Such fixturing systems are the best way to ensure reliable functionality in a production environment. By using them, operators can make highly

sophisticated form and surface finish measurements quickly, easily, and most importantly, accurately. TAKING THE GAGE TO THE PART While most of the focus in the preceding examples has been on small, easily transported parts, there are many applications where it makes more sense to measure parts directly wherever they are rather than take them into a metrology lab or mount them on a gaging system. There are several rules for the design of such systems. First, in addition to shop-hardening the gage, the design must protect sensitive probe and drive components. It must allow access to the features to be measured. It must be designed to eliminate operator error as much as possible, and of course, it must be fast and easy to use. One approach has been to develop a series of modular fixtures, keyed to the requirements of specific components, that enable operators to simply place the fixture in the area to be measured, and with the touch of a single button or two, affect the entire measurement process. The fixture itself takes care of accurately positioning the gage, engaging the probe and taking and recording the measurement. A good example of this is the measurement of surface roughness in bores. This often is difficult due

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Fixturing systems are designed to improve the efficiency of staging small complex parts by orders of magnitude. These systems succeed because they are based on good, solid mechanical design principles and utilize basic kinematic mounting techniques. For each part, one or more mounting fixtures was designed. These, in turn, mount in another base fixture designed to mount on the measurement machine. The operator simply puts the part in the fixture, puts the fixture in the base, presses the appropriate measurement icon on the touch screen and the system takes the measurement. Source: Mahr Federal

to the size and depth of the bore. Typically, positioning the drive unit often leads to probe damage and drive unit positioning problems. The bore fixtures were designed to eliminate these problems by automatically positioning the measurement probe in the correct orientation. In one example, a dedicated bore fixture, mounted on the front of the handle assembly, accurately positions the probe in the area to be measured. During entry into the bore, the probe is in a protected position. A mechanical device allows the probe to drop into measurement position only when the plug is fully seated against the front of the bore. No opera-

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tor technique is required for orientation or protection of the measurement probe. Thus, by a combination of merging form and surface finish measurement, efficiently staging small complex components using intelligent fixturing, or designing gages that more efficiently measure parts directly, traditional tactile methods of surface finish can be employed more quickly and efficiently, and even with improved accuracy. Q Pat Nugent is vice president, metrology systems at Mahr Federal Inc. (Providence, RI). For more information, e-mail [email protected] or visit www.mahr.com.


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SOFTWARE & ANALYSIS

Document Control is a Cornerstone of Effective QMS

A document control system can have a direct impact on an organization’s ability to serve its customers. They need to choose whether it will be positive or negative. BY JIM L. SMITH

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The second reaction, particularly hen mentioning document if the organization has a certified control to most people the topic ISO 9001 quality management typically elicits two difsystem, is one of fear ferent reactions. The BENEFITS or dread. Auditors, first is more like a yawn. » Document control is more internal and external, Document control is successful if it is simple, pay particular attention not very interesting to intuitive, user-friendly, easy to document control, the majority, and many to monitor and effective at which typically results people do not find it a preventing the use of incorin frequent nonconforvery exciting topic. After rect documentation. mances. It is commonly all, how complicated can » In order to bring about conreported that document it possibly be? sistency and interrelationcontrol generates more While document ships governing an effective nonconformances than control is not terribly document control system, any other quality mancomplicated, it is highly there needs to be a system agement system (QMS) relevant to the effective or hierarchy. element. This is basicaldeployment of a variety » An effective document ly true but the reason is of quality management control system will provide that most organizations processes which have a documents to users quickly make document control direct impact on an orgaand not slow the process much more complicated nization’s ability to serve with lengthy and non-valuethan needed. their customers. added procedures.

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DOCUMENT OC M N CON CONTROL O IS ESSENTIAL Document control, as with many other systems, is more successful if it is simple, intuitive, user-friendly, easy to monitor and effective at preventing the use of incorrect documentation. Control of documents should be thought of as one of the cornerstones of an effective quality management system. Certainly it is not a glamorous activity. However, document control is an essential preventive activity that, when effectively managed, can ensure that once approved, current documents will be used throughout the organization. Inadvertent use of out-of-date documents, procedures, work instructions and the like can have significant negative consequences on quality, costs and customer satisfaction. There are numerous situations that can be used as an example of what can happen when the proper documentation is not available. A design engineering change was made for a chamfer (a beveled edge connecting two surfaces on a machined outside diameter of a shaft to a corner-break). Design draw-

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Established by a senior management position with the intention to provide direction for an organization to govern practices and behavior with regard to quality.

1. POLICY

2. PROCEDURE

3. INSTRUCTIONS

Documents that specify the way to perform activities in order to comply with its policies. (What? When? Where? Who?)

Detailed, step-by-step, instructions for doing the work. (How?)

4. DATA

Recorded data and information that something has happened (history) that demonstrates compliance with documented and approved requirements.

In the pyramidal structure each level in the structure interlocks with and supports the next higher level.

ings were changed and manufacturing engineering (ME) notified. The ME made the change to the work instructions per procedure; however, the work instructions were not updated in the system. Consequently, the change was not implemented and failed to

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be detected until the new parts were assembled into units that reached field operations. The result was a significant field rework program with hundreds of thousands of dollars in failure costs and the loss of customer confidence, which translated into lost sales.

IT’S AN INVESTMENT Because of the importance to the business, more and more organizations are investing heavily in dedicated staff and detailed procedures. In the past, document control was an “add on” to someone’s responsibility. Today, it is an


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SOFTWARE & ANALYSIS area of growth in the jobs market; with high demand and potential high pay that crosses over to multiple industries. However, there is really no formal training available. There are no college courses, let alone a degree program, which directly train anyone into this profession. People working in this arena have had to learn the skills and techniques on their own. With many customers and suppliers requiring quality management systems in order to be certified, there have been a plethora of specialized software programs created to assist them in the control of their QMS and other business-related documents. This has been helpful, but it brings about other required skills in managing the overall system, which will not be discussed in this article. Information contained in documents, procedures and work instructions drives nearly every action in any organization. The ability to control this information means the difference between success or failure. Control of documents, therefore, remains the single most important quality assurance discipline.

It is easier to control a smaller number of documents than a large number. While this seems elementary, there are many examples where organizations appear to think the quality of their document system is directly proportional to the quantity of documents and records. A good document control system starts with document design and an understanding of the hierarchy and structure of documents. Document control administrators should be concise and work to keep the documents simple and multipurpose, when possible. An annual documentation review to uncover redundancies, obsolete documents and opportunities to consolidate will enable an organization to keep their documents lean, while effective, but with less cost. Recently, a quality manager in an ISO 9001 certified organization worked to streamline the company’s document control system. With the goal of reducing administrative costs while maintaining an effective document control system, the quality manager was able to implement a 43% reduction in their overall costs to maintain and control documents.

BRING ON THE HIERARCHY In order to bring about consistency and interrelationships governing an effective document control system, there needs to be a system or hierarchy. Arguably many organizations have been in existence for decades, managing their processes without much, if any, formal documentation. Some of these organizations continue to ship products that meet their customers’ specifications. However, in today’s environment, significant changes are impacting every organization. These dramatic changes are forcing organizations to change in order to remain competitive. These changes are causing organizations to become much more formal and structured. One model for structuring documentation is the pyramidal structure, with each level in the structure interlocking with and supporting the next higher level. This model is effective because it offers a logical arrangement that clarifies authority and interrelationships of each document. Lower-level documents must agree with requirements of related

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higher-level documents. Similarly, higher-level documents typically reference lower-level documents to drive connectivity. The message in many organizations is that lower-level documents cannot be in conflict with upper-level documents. The goal is not to be inflexible, but to ensure an organization is performing work in a consistent and efficient manner to deliver customer expectations. While the basic tenets of document control are fairly simple, implementing and managing an effective and efficient document control system can be a challenge. Documents are not individual, stand-alone elements of the management process. They are interrelated, formatted in different media, and typically controlled by various and distinct functions. Keeping critical information current, in the right hands of the right people at the right time, requires more than just signing off (approving) on procedures. Document control is essential, but where should you begin? WHERE TO BEGIN Maybe the simplest suggestion is to use the ISO 9001 quality management system requirements even if an organization is not interested in working toward a certifiable quality management system. ISO 9001 requires, and always has required, an organization to have a documented quality management system, and not a system of documents. It is very flexible, so it can be adapted to fulfill most organizational needs. Simply work down the list of document control issues outlined in the requirements and briefly describe what the organization is doing for each one. Keep it simple and avoid creating too much bureaucracy. An effective document control system will provide documents to users quickly and not slow the process with lengthy and non-valueadded procedures. Philip B. Crosby once said that, “an organization that establishes a quality program will have the ability to do what it agreed to do.” Isn’t that what a document control program is all about? It is a direct reflection on the organization’s personal integrity and intensity about getting things done properly to satisfy the needs of their customers. A effective document control system results in an organization having the

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data and information to properly train personnel, provide a basis for measuring performance, emphasize a consistent method of doing work, analyze trends, assess risk and benchmark good practices. It supplies the road map on how to do things correctly and establish a baseline for improvement. Q Jim L. Smith has more than 45 years of industry experience in operations, engineering, research

and development, and quality management. For more information, e-mail faceofquality@ qualitymag.com.

QUALITY ONLINE For more information on document control, visit www.qualitymag.com to read the following articles: • “Document Collaboration and Control” • “Document Control Advances Quality” • “Manage Metrology Documentation”

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MANAGEMENT

Supply Chain

Quality Begins With You

Some tips will help get you started on the supply chain quality road. BY MARK NASH AND SHEILA POLING

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that we all too often fall back on our uch has been written about qualold and comfortable ways of project ity throughout the organization. management vs. lean improvement. Likewise, much has been written about Tackling all of the quality issues withlean and how the principles of lean are in the supply chain can be overwhelmrolled out into a company. So when ing. First, there are all of the problems the subject of supply chain quality is presented by all of our suppliers. Then approached, why do so many organizathere are the infinite, and seemingly tions struggle with how to make subnever-ending, quality issues within our stantial and long-lasting improvements own four walls. And finally, we are faced to quality issues? with the dilemma of responding to our Is it because lean concepts were customers’ demands; accepting the fact embraced so late in the game by the that the customer is always right (or are purchasing world, or because the sales they?); and then attempting to work team in your company is around these issues so as still fighting about how BENEFITS not to upset the customer lean applies to them? Seven Steps to Get Started or lose sales. Perhaps it is because we with Supply Chain Quality So where should you tend to leave this piece for 1. Identify the issues start to improve quality our quality department 2. Categorize the list throughout the supply to fix? Or is it because chain? How about startwe are talking about the 3. Identify root cause ing with you? Whoever extreme breadth of the 4. Implement change where you are, whatever your job whole situation; optimizyou are in control is, this is where it starts. ing quality from supplier 5. Look for partners, both After all, for most of us to customer? customers and suppliers there is no way to correct The answer most often all of our issues at once. So identified with this ques6. Help them help themselves and you why try? Start with what tion is a combination you can control. Don’t fall of the aforementioned 7. Remember, it is continuprey to the argument that thoughts, plus the fact ous improvement

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the quality of materials coming in the door must be improved before “we can make real improvements.” How many times has your organization sat around and argued and complained that your customers do not have their ducks in a row; they cannot ever seem to place an order error free; or the ultimate complaint, “We don’t have a clue what the specifications from this customer are?” If your team is sitting around having these discussions about your customers, wouldn’t it seem that your suppliers might be saying the same thing about you? Using the lean philosophy of improving every day, attack what you control. Right now—not tomorrow or the next day. Not after your suppliers get their acts together. Now. Not after your customers understand what it is that you need from them and can send you the correct information each and every time. Now. Sounds simple enough. And it truly is. READY, SET, GO So how do you get started? 1. IDENTIFY THE ISSUES Spend time identifying the issues by utilizing a problem-only brainstorm session with your team. Be sure to include representatives from all affected areas—purchasing, production,

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Where should you start to improve quality throughout the supply chain? Whoever you are, whatever your job, it starts with you.

engineering, quality and sales—on the team. Use a facilitator to keep the session moving forward and to avoid members trying to solve problems on the spot. This meeting should generally last less than 30 minutes. If the list gets too large or the issues too deep, remind everyone that you do not have to solve all the problems of the world at once.

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Continue to look around for quality issues that you can improve and repeat the cycle time and time again. The cycle must become the culture of your organization to truly be successful.

2. CATEGORIZE THE LIST Review the list and quickly assign each item to one of three categories: supplier, internal or customer. Do not allow anyone to place an item into more than one category. If they try, and one category is internal then place it in the internal bucket. For other items that are both supplier

and customer issues (if there are any), allow the person that placed the item on the list in the first place the task of deciding into which bucket it should be placed. After the items are all categorized, take both the supplier and the customer lists and parking lot them— set them aside for now and revisit them when you are ready to work on step 5.


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MANAGEMENT 3. IDENTIFY ROOT CAUSE Take the list (or bucket) of issues that have been categorized as internal, and before performing root cause analysis, prioritize the list based upon whatever criteria your team chooses. Then, and only then, begin conducting root cause analysis on each item on the list from most important/critical to least important/critical. Whether you use the 5 Whys method, Ishikawa Diagram, Pareto Analysis, Kepner-Tregoe RCA or some other tool to determine root cause, make sure you complete this step. It is critical to systematically attack problems based on facts, not hunches or opinions. 4. IMPLEMENT CHANGE WHERE YOU ARE IN CONTROL As you identify root cause and determine what changes must be made to correct the problem, do not wait. Using lean logic, once you know what to do—do it. Do not think you need to implement change according to priorities. It may take considerably longer to identify the root cause of

your highest priority quality problem than one much farther down on the list. Use the lean mindset of making something better today—right now. Your goal at this stage of the game is to make improvements as quickly as possible. The improvement may not be perfect, but if it is better than it was yesterday, you are headed in the right direction. 5. LOOK FOR PARTNERS, BOTH CUSTOMERS AND SUPPLIERS When you begin to notice that quality concerns in your small piece of the world are getting better, it is time to start spreading your success outward. First, to other parts of your organization, and then to your suppliers and customers. You do not have to be perfect internally before you start spiraling out, but your improvements had better be noticeable. Noticeable to your internal customers as well as your ultimate customer. Noticeable not just to your internal supplier, but all the way back through the supply chain. People need to be holding you

up as a model for quality improvement. That does not mean error-free, it simply means that the changes are real, apparent and measurable. This is the point in the process when you revisit the parking lot looking for opportunities with suppliers and customers. This also may be the most critical part of the supply chain quality improvement process. Looking over the two categorized lists identify other organizations that appear to the team to already be partners, or their mindset is such that your team members believe they are good candidates for partnering. You may want to seek information from others in your company for more input on this subject. Once identified, find issues on the list from that particular bucket for the candidate company that can be improved. Your goal is to find common ground with the supplier or customer where you can work with them to solve quality issues that make both organizations better, more profitable companies. This is where companies such as Pelco Products Inc. (Edmond, OK), have set themselves

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apart from their competition. Pelco, the 2010 Quality Magazine Plant of the Year, is focusing a considerable amount of effort to create partnerships with both suppliers and customers in pursuit of improved supply chain quality. 6. HELP THEM HELP THEMSELVES AND YOU While Pelco has spent some time working with several customers to help them establish lean supermarkets and to use kanbans to reorder product, the most powerful results to date have come from partnering with suppliers to improve the front-end of the supply chain. Working with Tower Extrusions Ltd. (Olney, TX), Pelco’s lean experts toured Tower’s facility in Texas. From this tour and the candid discussion following, Pelco worked with Tower management to create a game plan where Pelco staff conducted a lean training class, facilitated a lean kaizen event and worked with the Tower management team to identify an internal lean facilitator. With a game plan in hand, Tower Extrusion is now heading into its own

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lean journey. Significant cost savings have already been realized through the training and assisted kaizen events. Pelco, in return, has seen improved quality and reduced lead times on product purchased from Tower. Even though Pelco staff has repeatedly explained to Tower management that this is a win-win partnership, Tower’s General Manager Mark McClelland continues to be amazed. “I just can’t believe that one of our customers would come help us. And then when they loan us their managers and lean experts to get us started, they only ask to be reimbursed for actual cost in return,” he says. “We can never repay Pelco’s assistance. This partnered effort has set the stage for our lean and quality journey for years to come.”

Continue to look around for quality issues that you can improve and repeat the cycle time and time again. The cycle must become the culture of your organization to truly be successful. So, do not sit around waiting for your suppliers to get quality right first. It starts with you. With a little luck and a lot of hard work you will soon be joined by customers and suppliers working to achieve the best quality for everyone. Q

7. REMEMBER, IT IS CONTINUOUS IMPROVEMENT Even as success after success is realized, remember that this is continuous improvement. The effort started with you and what you could affect immediately. And ultimately it will come full circle.

QUALITY ONLINE

Mark A. Nash is operations manager for Pelco Products Inc. (Edmond, OK). For more information, call (405) 340-3434, e-mail mark.nash@ pelcoinc.com or visit www.pelcoinc.com. Sheila R. Poling is a managing partner in Pinnacle Partners Inc. (Oak Ridge, TN). For more information, call (865) 482-1362, e-mail srpoling@ att.net or visit www.pinnaclepartnersinc.com.

For more information on supply chain quality, visit www.qualitymag.com to read the following articles: • “Achieving Quality ROI Across the Supply Chain” • “Build Better Metrics, Build Better Product” • “Strengthen the Six Sigma Portfolio”


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CASE STUDY The Galileo AV 300 was bought in parallel with the decision to steer the business toward clean room injection molding. Mold validation studies performed at Tegra Medical involve making tens of thousands of parts very quickly and making hundreds of measurements at well-defined intervals. Source: Starrett

VISION FOR

THE FUTURE Tegra Medical scales up vision measurement capabilities to support integrated medical manufacturing opportunities.

T

• Validating special processes to egra Medical (Franklin, MA) is ensure repeatability, minimize counting on its culture of quality to inspection time and reduce cost. keep existing customers satisfied and • Training employees to to attract new business. continuously improve Quality at Tegra involves BENEFITS critical skill sets and much more than inspect» With the AV 300 system it integrate quality ing every nth part. It is a takes a few hours to write disciplines into every total program designed to the program to set up a aspect of the comlimit the customers’ quallarge mold validation during pany’s business. ity risk exposures by such which the same two or three • ISO 13485: 2003 certimeans as: CTQ features are measured fication and FDA QSR • Examining first on a large number of parts. compliance. pass yields. » Programming is simple • Using real-time statistibecause it keeps all the With quality being cal process control (SPC). needed tools, directly on the so central to everything • Employing Six Sigma desktop just as they are with modern computer-aided the company does, Black Belt engineers who design (CAD) systems. one might think that use lean manufacturing selecting vision-based protocols to eliminate » Because the system feeds inspection equipment waste and remove variaall the data into an Excel would be a routine tion from manufacturspreadsheet, transcription errors are eliminated. and straightforward ing processes.

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exercise. According to Maurice Leger, senior process quality engineer at Tegra’s Dartmouth, MA, facility, this was not the case. Dartmouth has just upgraded its vision inspection capabilities by adding a new The L.S. Starrett Co.’s (Athol, MA) Galileo EZ200 manual vision system and an automated Starrett Galileo AV 300 multisensor system. This acquisition allowed Tegra to augment or replace reliable older microscopes, comparators and vision systems that have been used at the plant for many years, with systems that are far more accurate, repeatable, and easier to program and use. Leger, who led the search during which his team evaluated several brands of multisensor systems, explained that new vision-based systems would be involved in diverse applications. These include first piece inspections, traditional in-process part validation, random roving inspections, mold validation studies (for the plant’s newly launched clean room) and Six Sigma manufacturing process qualifications, in addition to generating geometric data and analyses that could be shared across multiple divisions and with the company’s Genesis Tech Center in support of rapid response manufacturing projects. So finding vision-based measurement systems that provide the best fit for all of these present and anticipated uses was a very exacting process. The primary driver in acquiring the multisensor measurement capabilities was the expansion of the division’s focus from the precision grinding of needle products into Class 8 clean room overmolding of completed products incorporating the needles and subsequent medical device assembly and packaging, including Class III medical devices. Leger says, “The Galileo AV 300 was bought in parallel with the decision to steer the business toward clean room injection molding. Mold validation

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CASE STUDY

The AV 300 system at Tegra Medical is equipped with a tactile probe that can reach in and collect data from areas of the part where the geometry obstructs the video sensor. In the past, inspectors had to cross section parts to measure these areas. Shown on the left is a profile inspection measurement sample and on the right in a worm tool sample. Source: Starrett

studies performed at Tegra Medical involve making tens of thousands of parts very quickly and making hundreds of measurements at welldefined intervals. The object of the game is to determine which settings in the machine I will use to get the best results out of every cavity. For this purpose we needed a system that is fast and easy to program, extremely accurate and capable of automating the

measurement of large numbers of parts in a very small window of time.” Today, with the AV 300 system it takes a few hours to write the program to set up a large mold validation during which the same two or three CTQ (critical to quality) features are measured on a large number of parts. Programming is simple because it keeps all the needed tools, directly on the desktop just

as they are with modern computeraided design (CAD) systems. Because the system feeds all the data into an Excel spreadsheet, transcription errors are eliminated. It takes about a day to measure the parts, collect the data and complete the study. This reduces the mold validation process by days while improving accuracy and eliminating many sources of potential error.

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The AV 300 system at Tegra Medical is equipped with a tactile probe that can reach in and collect data from areas of the part where the geometry obstructs the video sensor. In the past, inspectors had to cross section parts to measure these areas. Cross sectioning is a very labor intensive and delicate procedure that adds hours to the measurement process. Tegra hopes that the AV 300 will dramatically reduce need to crosssection to mold validation and process studies even faster. While the company was evaluating advanced video measurement systems for its laboratory, it was looking to upgrade the manual measurement capabilities that relied on optical equipment of a previous generation. Operators employ these systems on the shop floor, so they have to be rugged, fast and easy to use. Leger discovered that it was possible to emulate the cross-hair alignment mode of operation used by the older style equipment with Starrett’s Galileo EZ200 manual video measurement system. Therefore,

Tegra’s Dartmouth facility has very accurate video measurement tools that it can use not only to meet today’s needs, but also adapt to future requirements. Source: Starrett

operators got the benefit of higher accuracy, repeatability and more magnification with a system they could be comfortable with after just a few minutes of training. Because quality operations management spans all of the Tegra Medical’s divisions Leger wanted to confirm that this style of measurement would suit the needs of everyone working on projects that span multiple divisions. So shortly after installing his systems in Dartmouth, he had the quality team

from the Franklin, MA, plant come in to look at what he was doing. They liked what they saw. Soon they were asking Leger to do some profile measuring for them. It was not long before the Franklin plant installed a Galileo EZ200 system of its own. Now Tegra’s Dartmouth facility has very accurate video measurement tools that it can use not only to meet today’s needs, but also adapt to future requirements as the company customizes and fine-tunes manufacturing processes to meet the needs of its exacting customers. Leger says, “When the Galileo AV 300 first came in I told just about everyone we were about to land a spaceship in the middle of the plant. It is much more accurate and capable than systems of the past. At present, we are only using a fraction of those capabilities, but we can easily turn them on or off as needed going forward to accomplish our goals.” The L.S. Starrett Co. (978) 249-3551 www.starrett.com

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August 2011 | QUALITY 51PM 1/13/09 2:05:07

CASE STUDY After implementing the Discus software, Darchem was able to initially reduce the time of the first article inspection process by 50% and since then, 60% to 70%. Source: Discus Software

TAKE THE

HEAT OUT OF THE PROBLEM Software improves the time required to complete the critical first article inspection process.

D

The Aerostructures business unit archem Engineering Ltd. is based serves the aerospace and defense in the United Kingdom and speindustries. Customers include major cializes in providing engineered soluUK, European and North American tions to high temperature/thermal engiairframe and engine manufacturers. neered problems. Supplying primarily Darchem engaged with Discus after to the aerospace, energy, automotive a leading UK aero engine company and marine markets, Darchem is a subannounced it would begin allowing its sidiary of the Esterline Corp. (Seattle). suppliers to submit first article inspecTim Marshall, quality manager of tion reports electronically. Darchem the Aerostructures business unit at took a proactive approach and Darchem Engineering, searched for the right says, “We tell our customBENEFITS software package for the ers that we can take the » The time of the first article job. “We had heard that heat out of their probinspection process was iniDiscus was the market lems.” Soon after becomtially reduced by 50% and leader in electronic FAI ing a Discus (Columbus, since then, 60%–70%. software and it had the OH) software customer, » The software takes a great best overall package,” Marshall says that deal of time out of the Marshall says. Darchem discovered that labor-intensive preparaThe first sign that the software improved tion process, which can involve gathering a large told Marshall that the time required to number of dimensions Discus was the right complete the critical first and specifications. partner for them was article inspection (FAI) the team approach to process required by many » Darchem realized a return Darchem as a customer. of its customers. on investment in six months.

52


“The team listened to what we wanted rather than forcing us to listen to what they could offer; that was quite refreshing. They also said, ‘We understand exactly what your needs are and what your customer base is going to need.’ A package was then tailored to suit Darchem’s requirements instead of offering us a one-size-fits-all package.” Marshall says that he also liked how intuitive the software was to learn, enabling inspectors to put it to immediate use in the FAI process, as well as how easily the software can be adapted to the unique requirements of each of Darchem’s customers. “We knew once we tried it that it was very much the software package we wanted to bring in. We have been able to demonstrate to our customers that Discus was the right company to partner with,” says Marshall. Marshall says that Darchem now recommends Discus to its suppliers based on proven experience, and he is confident other UK companies could benefit from using their software. “In fact,” Marshall notes, “some of our key customers have also selected Discus as their preferred provider of electronic first article inspection reports (FAIR).” A major benefit of the software package for Darchem is time savings. Marshall notes, “We were able to reduce the time of the first article inspection process by 50% initially, and since then, 60% to 70%.” He says that the software takes a great deal of time out of the laborintensive preparation process, which can involve gathering a large number of dimensions and specifications. Darchem delivers FAIR right the first time, and Discus has allowed Darchem to save a substantial amount of time. “The fact that we are able to deliver the first article inspection reports right and in a timely manner plays a pivotal role as program timescales are often under pressure at this early stage. It gives the customer the confidence that we have the ability to manage the proj-

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ect effectively…and that helps satisfy the customer that they’re dealing with the right supplier.” As a result of the time savings from using the software, Darchem realized a return on investment in six months, Marshall says. “I was expecting ROI in the first year. That would be good. But we were able to demonstrate to the directors here at Darchem a pound for pound savings—the Discus software gave us a six month ROI, in labor savings alone.” From the good experience of the Aerostructures division, the company has purchased additional licenses for its other divisions, which are now also benefiting. Marshall points out, “Customer support has been outstanding. In many cases, it has involved getting answers the same day. This allows Darchem to complete the documentation and deliver the first article reports to the customer on time. We didn’t expect to get answers the same day. That is impressive, particularly since we are located in the UK

Darchem discovered that the Discus software improved the time required to complete the critical first article inspection (FAI) process required by many of its customers. Source: Discus Software

and Discus is based in the U.S. The adoption of Discus by other major European aerospace companies provides a further degree of confidence in the product.”

Discus Software Co. (614) 360-2424 www.discussoftware.com

ASNT Fall Conference & Quality Testing Show Palm Springs Convention Center Palm Springs, CA, USA 24-28 October 2011

See the NDT Industry Bloom in the Desert

See program details online; visit www.asnt.org/events/events.htm. www.qualitymag.com


53

2011

CASE STUDIES SPECIAL A DVERTISI N G SEC TI O N This Case Studies Special Advertising Section features manufacturing companies with real-world challenges using quality equipment, software and services to solve their problems and improve their processes. These problem-solving stories describe myriad manufacturing challenges and how the correct application of a supplier’s product or service made the difference, providing quantitative benefits to quality and manufacturing issues. The suppliers in this special section present these real-world problems and solutions to help Quality Magazine subscribers who may have similar experiences.

ADVERTISER CASE STUDY INDEX ADVERTISER

54

PAGE

CASE STUDY TITLE

Bal-Tec Division, Micro Surface Engr. Inc.

59

BALL BAR - DUMBELL

Carl Zeiss Industrial Metrology

55

CMM Learns New Tricks by Moving to CALYPSO Software

Cybermetrics Corp.

56

With GAGEtrak, Hlliburton Improves Measurement Quality

Diatest Gages & Tools Inc.

60

Diatest BMD Production Bore Gages

Gradient Lens Corp.

60

Borescope Assure the Quality of Mission Critical Aviation Parts

Heidenhain Corp.

57

Did you know…

Hommel- Etamic America

61

Optical shaft inspection is a H-O-G

Intelex

59

Integrating Your Quality Management System

Mark 10 Corp.

62

180 Degree Peel Testing

Marposs Corp.

55

Cutting the Cables

Micro-Vu

63

Multi-Sensor Machine Replaces CMM

Mitutoyo America Corp.

58

Assuring Performance of Long Gage Blocks

NSF International

56

Want Effective Cost and Risk Management?

Perceptron

63

FLEXIBLE MANUFACTURING SUPPORT

Qioptiq Linos Inc.

64

Increasing Metrology throughput without compromisng quality

Renishaw

61

New 5-axis head for touch-trigger inspection on CMMs

S-T Industries Inc.

64

Save $$$$$$

Scienscope

58

Inspection of Over Molded- Encapsulated Medical Devices

Starrett Co., The L.S.

62

Porsche Motorsport North America

Verisurf

57

SpaceX Demands Precise Positioning

Yxlon International

65

CT Solutions- Industrial Computed Tomography Stystems


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CMM Learns New Tricks by Moving to CALYPSO Software DeZURIK is a global leader in manufacturing water and wastewater treatment valves as well as many other valves. They have been using a Brown and Sharpe CMM (coordinate measuring machine) system for 11 years for various quality measurement processes. In 2010 DeZURIK had the need for decreased part programming times, reduced operating costs and they were also due for a software upgrade on their current measurement system. Cone and angle measurement complications were of special interest and they were curious as to how CALYPSO would handle these measurements. After software demos and cost comparisons, DeZURIK decided to purchase a CALYPSO software upgrade from Carl Zeiss. CALYPSO would easily work on their Brown and Sharpe CMM, would decrease part programming time and would cost less than an upgrade on their previous software. The CALYPSO software is very user friendly and easy to use. “With our previous linear programming code setup, if you didn’t write the part program, you really had to study it to determine where the measurements were coming from,” says Keith Feddema, quality engineer at DeZURIK.

Benefits of CALYPSO’s objectdriven measuring tasks and visual metrology for DeZURIK: • multiple operators can easily use programs • part programming time reduced 50 percent • angles and cones easily analyzed with different calculation tools • measurement plans easy to organize, no complex code • printed graphics improve measurement communication with R&D and customers • can perform more first article inspections DeZURIK is now able to use CALYPSO software for even more measurements in various applications.

Carl Zeiss Industrial Metrology 6250 Sycamore Ln N Maple Grove, Minnesota, 55369 Phone: 1-800-327-9735 E-Mail: [email protected] Internet: www.zeiss.com/metrology

Cutting the Cables

Cases for the high-efficiency gearboxes produced by Fertigungstechnik Nord in Gadebusch, Germany, are machined from solid castings at an annual production volume of over 280,000 units. The company has extensive experience with networked automatic gauging systems used in the shaft manufacturing area. These systems automatically measure production shafts and provide compensation feedback to the controls to maintain quality. However, that approach is not feasible in the case machining area. Equipping all of the machining centers with fully automatic measuring devices would be economically unfeasible. But the company has been able to obtain many of the same benefits by changing from conventional cable-connected plug gauges to M1 Wave Wireless gauges from Marposs.

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The most obvious benefit of a wireless solution is the elimination of cables, and that is no small advantage when a typical workstation has a dozen or more gauges, each with several yards of cable attached. The safety impact of removing those cables from the working environment is self-evident, and eliminating the maintenance cost associated with them produces significant operating cost savings as well. In addition, eliminating the cables also eliminates a major source of interference and incorrect gauge readings that cost employees precious time at the machines. The new wireless gauges have substantially reduced error rates. Combined with the display electronics in the form of networkable PC technology and the process-oriented software solution, the new measuring systems ensure a high measuring reliability. In addition, Nord has implemented traceable documentation of the measured data that are manually collected in the case manufacturing plant. For more information on Marposs M1 Wave wireless bore gauges, please visit the company’s website at www.marposs.com or contact the company by toll-free telephone at 1-888-627-7677 or by e-mail at [email protected]


55

2011 CASE STUDIES

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Want Effective Cost and Risk Management? NSF-ISR can help. Other benefits PBUD experienced include: Cost Savings. With a management system commitment to continual improvement, operating expenses have maintained an average fiscal year savings of 9 percent since certification. This savings easily offsets the cost of EMS implementation. Reduced Liability. Through an EMS protocol to identify environmental aspects and associated risk, the utility used its EMS to reduce environmental and associated business risks. Within a year of certification, Standard & Poor’s raised PBUD’s bond rating to an ‘A’ based on reduced risks. The higher bond rating enables the utility to borrow money at lower interest rates and stabilize customer costs while maintaining service levels. NSF-ISR partnered with PBUD to conduct an ISO audit and identify areas for improvement. NSF-ISR’s expertise in quality and EMS enables us to focus on a variety of industries with confidence. Our diverse auditor base compliments our technical expertise, providing the total solution your organization requires.

NSF International Strategic Registrations (NSF-ISR) offers solutions to help our customers grow and innovate in their industry sectors. Palm Bay Utilities Department (PBUD) Environmental Management System (EMS) was one of the fi rst water and wastewater utilities in the state of Florida to receive certifi cation under the ISO 14001:2004 EMS standard. As a result of the EMS, the department achieved a 31 percent reduction in energy use for its water treatment plants from 2007 through 2010. The utility was recognized with a number of awards, including the Association of Metropolitan Water Agencies (AMWA) Gold Award for exceptional utility performance.

Contact: John Arvay ([email protected]) 734.657.4567 www.nsf.org

®

WITH GAGEtrak , HALLIBURTON IMPROVES MEASUREMENT QUALITY IN ENERGY TECHNOLOGIES Founded in 1919, and

Paredes says. She also

with more than 60,000

notes that her favorite

employees worldwide,

GAGEtrak features are

Halliburton serves the upstream oil and gas industry throughout the

“the calibration due list

life cycle of the reservoir – from locating hydrocarbons and managing

and the ability to devel-

geological data, to drilling and formation evaluation, well construc-

op custom reports.”

tion and completion, and optimizing production through the life of

Paredes has also had

the field.

great success with CyberMetrics’ support team, commenting that

Challenge: Responsible for ensuring that the company’s several thousand gages are properly managed, tracked and calibrated, Halliburton’s

Kathy

“the support team is very helpful and they teach me something new every time I call.” Impact: Halliburton found GAGEtrak to be such a valuable asset

to

that since 2005, they’ve installed GAGEtrak at an additional 61 loca-

save time, reduce cost-

tions worldwide. Halliburton continues to use GAGEtrak “because it

ly errors and inconsis-

is the best fit for all locations whether they calibrate their own gages

tencies associated with

or have them outsourced.”

Paredes

needed

tracking

GAGEtrak is used at thousands of facilities worldwide to improve

data via spreadsheets

measurement quality, assure compliance and increase efficiency.

and implement compa-

Contact CyberMetrics today to learn how GAGEtrak will do the same

ny-wide standardization

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storing

and

of gage and calibration data. Solution: GAGEtrak® Calibration Management Software by CyberMetrics. Halliburton initially installed one license of GAGEtrak at a single location in early 2005 because it is “easier to use and has a place for all the required information to maintain our gages,”

56


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DID YOU KNOW…

…that a HEIDENHAIN GAGE-CHEK metrology digital readout (DRO) is a vital component in the new and truly unique in-process honing and air gaging system now available to high precision metalworking businesses? Called PAGS (Precision Air Gage System), this new technology is available from Bates Technologies LLC in Fishers, Indiana, and is being installed for its customers by select global machine tool builders such as Mazak Corporation and others who want to offer a superior, integrated honing and gaging system directly on a machining center. Typical honing systems are standalone, dedicated machines. The flexibility provided by the in-process PAGS honing system incorporated into a machining center effectively eliminates the need for the

dedicated equipment as well as streamlines the process resulting in a significant cost-savings for the end-user. “This really has been a collaboration of experts over the last few years in order to enable this important paradigm shift in honing and air gaging for use on flexible and agile platforms,” said Darrell Day, president of Bates Technologies. “The overwhelming support and expertise from HEIDENHAIN has contributed into allowing our PAGS to talk to our customers’ PLCs and make this truly an in-process system.” The PAGS in-process gaging system for use on CNCs includes the use of a controlled air pressure. This information is passed onto the GAGE-CHEK unit which has been programmed to monitor the changes in bore size during the process. This information is visually available to the operator through the unit’s DRO function. As the bore size grows larger with each stroke of the honing tool, the gaging unit mounted on the side of the machine displays its dimensions in microns, and when the correct size is reached, the CNC machine PLC is fed information from the GAGE-CHEK to notify it to complete its cycle, and automatically stops.

Kathleen Stoneski HEIDENHAIN PR Manager, North America [email protected] 847-895-0945 847-519-4702

SpaceX Demands Precise Positioning software. “With Verisurf, we are looking directly at the CAD model and the measurement results,” stated Larry Mosse, SpaceX’s tooling operations manager. “We see the measurements reflected against the 3D model. This makes the process faster and reduces mistakes.” He continued, “We aren’t drawing free, yet, but like the rest of the aerospace industry we are striving to implement model based definition to achieve its many benefits.” For SpaceX the most important benefit is time. Model based definitions (MBD) with profile tolerances eliminate the time to document an engineering drawing; reduce the time to create inspection plans and reports; and accelerate identification and resolution of manufacturing issues. To read the whole story visit us at www.verisurf.com or contact [email protected] With the retrieval of Dragon from the Pacific Ocean, Space Exploration Technologies (SpaceX) became the first commercial company to launch and recover a spacecraft from low-Earth orbit. Placed into space atop the company’s Falcon 9 launch vehicle, Dragon completed two orbits with speeds topping 17,000 miles per hour. After its three-hour, fifty-thousand-mile flight, Dragon splashed down just one mile from the center of its targeted landing zone. The accuracy of the flight path required careful alignment of Falcon 9’s sections and precise launch vector positioning. So, the SpaceX crew used its PCMM metrology systems, which included laser trackers and Verisurf

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Verisurf Software, Inc. 1553 Harmony Circle, Anaheim, CA 92807 P 888.713.7201 • F 714.701.0280 www.verisurf.com


57

2011 CASE STUDIES

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Assuring Performance of Long Gage Blocks By: Amosh Kumar, Laboratory Manager Mitutoyo America Calibration Laboratory, Elk Grove Village, Illinois McNeal Tool Company of Cedar Rapids, Iowa, a wholly owned subsidiary of Mid Iowa Tools, Inc., specializes in the sales and support of precision metrology instruments and services. This includes provision of gage calibration services to a national manufacturer of window and door products that are sold into residential and commercial markets. According to Wayne Schneider, McNeal Tool Field Application Engineer, “Many of the customer’s products include wood and extruded or roll-formed materials processed to length using tenoners, molder/profilers, or saws. The length of these pieces can measure from around 90” to 140” or more, with tolerances typically kept to within ± 0.002”. To help keep machining processes centered on nominal values, the customer utilizes an SPC measurement routine that includes periodic use of long, single-axis measuring tables specifically designed to verify accuracy of long workpieces. The measuring tables are about 12” wide, up to 140” long, and equipped with digital readouts. Accuracy of the measuring table set-ups is regularly verified utilizing an “assembly” of the longest available, standard gage blocks – these come in kits, generally with lengths of 5”, 6”, 7”, 8”, 10”, 12”, 16”, and 20”. These long gage block assemblies must themselves be periodically calibrated as error accumulates over time. Error can be introduced by: disassembly and re-assembly, nicks, burrs, dropping, oil and dirt build-up, corrosion, etc. To reduce inaccuracies, each gage in the set of blocks making up a long gage block assembly must be individually calibrated. Schneider explained that selection of a calibration services provider became increasingly important to the window manufacturer, saying, “Our customer had tried a number of calibration labs but couldn’t get consistent results. This was a real problem since inconsistencies are ‘multiplied’ by the number of blocks in each assembly. Finally, the window manufacturer settled on the Mitutoyo America Calibration Laboratory in Elk Grove Village, Illinois for providing the necessary level of performance.” The Mitutoyo America Calibration Lab uses reference masters that are directly traceable to NIST (National Institute of Technology and Standards).

To achieve high accuracies and low measurement uncertainty levels, the lab calibrates all instrumentation in a Class 10,000 certified clean room environment. When calibrating long gage blocks, temperatures are kept at 20º C ± 0.25º with relative humidity controlled between 40% and 60%. Access to the clean room is controlled by a positive pressure airlock to prevent entrance of outside air. Laboratory Best Practice procedures for measuring long gage blocks also include: • Verification of “single-point temperature stability” of the measuring station whereby temperature variation is verified to be less than 1/10 degree C per hour. • Real-time monitoring to make sure temperature gradients in the vicinity of the workstation remain consistent for the entire eight hours or more required to calibrate eight-piece long gage block sets. Schneider commented, “From choice of block material to the care taken in calibration lab procedures, our customer could see the how the benefits of Best Practice calibration translate from gage blocks, through measuring tables, and on to higher quality finished parts with lower rejects.”

McNeal Tool Company, Inc. 3350 Square D Drive SW | Cedar Rapids, IA 52404 Phone: (319) 366.2701 | Fax: (319) 366.8870 www.midiowatools.com Wayne Schneider, Field Application Engineer [email protected] Mitutoyo America Calibration Laboratory (Elk Grove Village, IL) 2025 Tonne Road | Elk Grove Village, IL 60007 Phone: (847) 593-7750 | Fax: (847) 593-7758 www.mitutoyo.com Amosh Kumar, Laboratory Manager Mitutoyo America Calibration Laboratory, Elk Grove Village [email protected]

Inspection of Over Molded - Encapsulated Medical Devices trical tests but often destroys the assembly and can easily obliterate or mask the actual component failure. If your intent is to repair the assembly and return it to the customer, the process of quoting the repair can become much more costly for you and your customer if you only use these three test modes in you evaluation and repair quote. Scienscope has solved these problems for numerous medical device manufactures by providing x-ray systems that allow the user to quickly inspect an assembly and make an informed decision in the control of a process or repair of the assembly. One manufacture was doing a visual inspection and electrical test before quoting the customer on the repair of a very expensive encapsulated assembly, by using the x-ray system for initial inspection they were able to reduce their labor costs in the evaluation phase and provide the customer with a faster and more accurate repair quote. Another manufacturer was visually inspecting over molded components and using a time consuming process of painstakingly removing the over molded materiel to revel the suspect area, x-ray inspection saved tens of thousands of dollars in overtime costs per year.

58

Over Molded and Encapsulated medical devices present a difficult

Scienscope International

challenge when investigating process issues or returns from the field

5751 Scheafer Ave

due to the nature of their design. Visual inspection and electrical

Chino CA 91710

tests provide very little information as to why the assembly failed

www.scienscope.com

internally. Destructive testing is a viable alternative to visual and elec-

[email protected]


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Integrating Your Quality Management System Solution & Implementation The company selected Intelex’s Integrated EHSQ Management System to do the job. Completely web-based, the system enabled employees across all locations to input quality, safety and environmental data into one centralized portal where it is easily accessed, reported, managed and analysed. Historical data was imported into the system, users were trained on key tasks and the system was swiftly deployed across all locations.

Though a standalone quality management system will suffice for many organizations, those that strive for continual improvement and understand the real value of data visibility employ an integrated approach to managing environmental, health, safety and quality (EHSQ) data. This is exactly why one of the world’s largest beverage manufacturers approached Intelex after identifying the need to unify isolated quality, environmental and safety systems into one integrated solution. Business Objective Since employees used different systems to manage EHSQ activities, organizational data existed in silos, could not be cross analyzed and required multiple personnel to access, retrieve and prepare it for management review. A centralized, user-friendly software solution to unify performance data and standardize processes was clearly needed.

Results Having all EHSQ performance data contained within one system provided the organization with real-time, 360-degree visibility. This allowed for faster and more extensive reporting capabilities of key operational data, better educated decision making and improved response times. Management can easily view dashboards instantly displaying any organizational performance data desired. The system’s ease-of-use resulted in more incidents and nonconformances being reported, allowing clearer identification of trends and prompt resolution of issues.

Website: www.intelex.com/ehsq For more information please contact JP Nadeau at [email protected] or 416-599-6009 ext. 345

BALL BAR - DUMBELL of $700.00. OUR Ball Bar found that the “Z” axis of this machine was out of square with the “X” axis 0.009” (0.23 mm). The “Z” to “Y” and “X to Y” Axii were perfectly square. After adjusting “Z”-“X” the entire machine was measuring within 0.0003” (0.076mm). He wondered if we had any suggestions on how he might improve this accuracy. As this was an older manual machine, we told him that we thought this was an acceptable accuracy. A simple, inexpensive Ball Bar-Dumbell system provides legal certification according to ANSI B 89.4.1 or VIM-VAR 260

Bal-tec Division We sold one of our $800.00 Ball Bar Kits to a young man who was

Micro Surface Engr., Inc. 1550 E. Slauson Ave

having problems with his C.M.M. Los Angeles, CA 90011 One week later, he call to discuss the results. His C.M.M. had just been serviced and certified by the machines manufacturer at a cost

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323-582-7348 www.precisionballs.com


59

2011 CASE STUDIES

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Diatest BMD Production Bore Gages are Perfect for Shop Floor After trying competitors bore gages Don settled on

This is a product built to perform without trouble for

Diatest, the reason was simple accuracy and reliability.

1,000,000 parts. The delivery is care free, lead times

“Other companies couldn’t offer the repeatability on

are posted in the catalog, and if you need one faster

tight tolerance jobs of a few ten-thousandths of an

express delivery is available, at only 12% more. Best

inch. Besides that the gages just hold up.” The bodies

of all the Diatest system can work with your companies

are hard chrome plated and the contacts are carbide,

existing handles and indicators with the help of adapters.

ceramic, chrome or diamond depending on what is

Call John to find out more about the advantages that

being measured. The materials used explain the long

Diatest can offer you.

life, but it is the Diatest design based on their split-ball system that gives them such high marks on durability.

Contact info.

“We are so sure you won’t break our plugs we offer a

John Nemec

lifetime guarantee on our contacts.”

Phone #800-DIATEST

Diatest has additional advantages over other manu-

Email: [email protected]

facturers as well, their 50 page catalog is packed with

Website: www.diatest.com

options and accessories. “We’ve been making bore gages for nearly 60 years and the BMD for more than 35 so we’ve picked up much experience along the way, that’s why we make more indicating plug gages than anyone.”

Borescopes Assure the Quality of Mission Critical Aviation Parts tion. Hartzell Propeller exclusively uses Hawkeye Precision Borescopes, manufactured by Gradient Lens Corporation of Rochester, NY. Hartzell uses Hawkeye borescopes exclusively because they are easily portable, dependable, accurate, and very cost-efficient. Because the company’s manufacturing and service operations are in multiple facilities, Hawkeye borescope systems can easily be moved from building to building as needed. Hartzell primarily use rigid borescopes, 7 to 22-inches in length, with a 0º direction-of-view (DOV). The Hawkeye’s can easily be changed to a 90º DOV by adding a mirror tube accessory. Hartzell also connects some borescopes to video systems for on-screen viewing and image capturing. When the entry Serving private, commercial, and military customers, Hartzell

path is not straight, Gradient Lens also carries a full line of flexible,

Propeller is one of America’s oldest aviation manufacturers. From

articulating borescopes, including fully portable video borescopes.

constant speed propellers, to governors, and deicing systems for propellers, Hartzell manufactures over 18,000 mission-critical parts and systems used on over 2,000 makes and models of aircraft. For products where contamination, dirt, or, surface finish defects

Gradient Lens Corporation www.gradientlens.com [email protected] 800-536-0790

could be a concern, Hartzell primarily uses visual inspection to verify that the product is acceptable. In tight locations to inspect such as small bores and blind holes, they rely on borescopes to conduct visual inspec-

60


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Optical shaft inspection is a H-O-G “We measure diameters to 4 microns with a gage R&R of 5%,” reports Clay. “You can’t touch that anywhere.” Hommel-Etamic’s Opticline noncontact CNC shaft gaging system measures form, dimensional, and positional tolerances of shaft-type parts in submicron detail with a maintenance-free two-camera system, recording results instantly. “With air gaging or hard gaging, there is a lot of setup and timeconsuming changeover, but with the Opticline,” Clay said, “I can change programs in about 15 seconds and be ready for the new part number. Flexible chucking helps also.” To create a program, Clay scans the part with the Opticline cameras, establishes a length of scan, and then starts a measurement cycle. “To accomplish the shaft measurements with air gages or ring gages, you would have multiple gages, which require setup, mastering, and maintenance. This adds up to greater cost over 3-4 shaft designs with a couple of sizes of each,” Clay said. The family of turbocharger shafts produced at Cummins Turbo Technologies, Palmetto, SC, have up to 11 diameters and various lengths—a complex part to inspect consistently and at rates that keep up with production. But Clayton Butler, metrology technician has a solution that has been working on the Cummins shop floor alongside the grinding machines for several years. He calls it his HOG -- the Hommel Optical Gage. Machine operators use the Opticline from Hommel-Etamic America to measure a shaft and turbine impeller wheel assembly for the turbochargers it produces-- diameter, runout, straightness, length. The staff also uses the gage on the shop floor alongside the grinders to measure an impeller mounted on an arbor. Each part is measured between centers in less than a minute.

Hommel-Etamic America 1505 West Hamlin Rd., Rochester Hills, MI 48309 Tel. 1-248-853-5888 www.hommel-etamic.com Email [email protected]

New 5-axis head for touch-trigger inspection on CMMs gives up to three-fold increase in throughput 5-axis technology enables faster and

a range of proven probe modules,

more comprehensive measurement for

providing a wide selection of trigger

improved process control.

forces, directional sensing options

Renishaw is introducing another

and extensions to meet application

innovative measurement product that

requirements. The detachable mod-

is expected to transform inspection

ules provide crash protection and can

performance on a wide range of co-

be automatically changed using the

ordinate measuring machines(CMMs).

MCR20 change rack. Companies with

Utilizing technology developed for the

existing TP20 systems will be able to

multi-award winning REVO® measure-

upgrade to PH20 and utilize their exist-

ment system, the new PH20 probe

ing modules.

head offers unique ‘head touches’

While REVO has set the benchmark

for rapid touch-trigger measurement,

for 5-axis scanning measurement on

and fast infinite 5-axis positioning to

larger CMMs, the exciting new PH20

guarantee optimal feature access. Its

probe head opens up access to new

compact design makes it suitable for

Renishaw technologies for most exist-

new CMM purchases and as a retrofit

ing users of CMMs.

to the vast majority of existing CMM

www.renishaw.com/ph20

Learn more at

touch-trigger installations. The new PH20 probe head also benefits CMM users with adaptive positioning to accommodate part misalignment, fast calibration routines, and an integral TP20 probe mount that optimizes the working volume of the CMM, bringing 5-axis capability to smaller machines for the first time. By incorporating the industry standard TP20 touch-trigger probe, users of the PH20 probe head will immediately have access to

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Renishaw Inc. Hoffman Estates, IL web: www.renishaw.com | email: [email protected] phone: 847-286-9953


61

2011 CASE STUDIES

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Porsche Motorsport North America Improves Performance with Starrett Custom Ride Height Gage Controlling race car height is one of the strictest rules in racing.

Porsche also utilizes the Gage’s output

Cars must be as

capability to transmit gage readings to

low to the surface of the track as possible to

their computer systems with the Starrett

achieve the best performance – dialing in the

DataSure Wireless Data Collection System.

proper ride height can mean the difference

DataSure provides Porsche with real-time,

between winning and losing.

error-free data collection to quickly analyze

Setting the optimal ride height level within

ride height data and make adjustments.

the rules requires the right tool. Porsche

With Starrett’s innovative, custom-engi-

Motorsport North America Racing turned to

neered gage, Porsche Motorsports has bet-

L.S. Starrett to develop a custom-engineered Ride Height Gage that provides easier, more precise measurement

ter accuracy, repeatability and traceability. Seems winning races just got a little easier.

before and after the race. Porsche uses the Starrett gage under the race car to measure from the surface where the tire sets up to buttons built into the chassis of the car. It is unique in that it offers two measuring units easily swapped out by hand as needed – faster, simpler and more accurate than competitors’ gages. Compared to other gages, it has a stiffer measuring axis, hardened surfaces and easy adjustment to measure width at different inspection points. In the American Le Mans Series, the race cars go rain or shine. Porsches’ previous gages produced readout errors or total shutdown at inspection in wet conditions. The new Starrett gage operates flaw-

Mike Sawin Engineering Manager, Starrett Special Gage Division The L.S. Starrett Company 121 Crescent St. Athol, MA 01331 978-249-3551 [email protected]

lessly in all weather conditions.

180 Degree Peel Testing - Determining the seal strength in packaging The amount of force required to open a bag of

test is consistent test speed, the ESM301’s pro-

pretzels or candy isn’t typically first and foremost

grammable speed ensures that the rate of peel

in our minds. Opening a package of snack foods

is consistent.

is normally a mundane affair – unless the package

An adjustable upper grip is attached to the

is too difficult or too easy to open. That’s when it

force gauge, pulling the material upwards, while

becomes more obvious that proper testing is criti-

the lower grip remains stationary. The force gauge

cal to achieving customer satisfaction.

records the maximum breaking strength. Then the

The testing of sealed pouches for such items

test stand’s crosshead reaches a limit switch and

as snack foods, medical devices, and consumer

returns automatically to the home position. The

products is often done to conform to ASTM D903

force gauge transmits data to a PC for further

and ASTM F88. These procedures call for a 1”

analysis in MESURgauge software. Anomalies in

wide strip of material to be pulled apart at the

peel force consistency can be viewed on a graph.

seal at an orientation of 180 degrees. A constant

Upper and lower acceptable force limits are deter-

rate of speed, typically 6” or 12” per minute, is

mined by the manufacturer, allowing for quick

required. The end result is a force measurement

identification of failures.

value, typically in Newtons or pounds. One manufacturer of snack foods has been

By Mark Fridman, Marketing Manager

performing such testing with their Mark-10 force

[email protected]

testing system, consisting of a model ESM301

Toll Free: 888-MARK-TEN

motorized test stand with digital force gauge and

Tel: 631-842-9200

pair of film & paper grips to secure each end of

Fax: 631-842-9201

the material. Since an important element of this

62


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Multi-Sensor Machine Replaces CMM To meet the needs of new medical customers and to stay ahead of competition, a precision plastic injection company in Santa Rosa, CA searched for a multi-sensor inspection system. They needed to measure smaller features, reduce programming time, reduce measurement time, and improve operator/programmer easeof-use compared to their CMM. The company selected the Micro-Vu Vertex 320 vision system with a 4-station touch probe kit and a 12"x12"x6" measurement capacity. The company retired its CMM within months. The company's metrologist began programming parts using Micro-Vu's InSpec Metrology Software during the first demonstration. Small holes, angles, gaps, and steps are programmed and measured in seconds. Previous "operators" become "programmers" with InSpec's point-and-click programming. Parts from multiple mold cavities are measured in a single inspection program and setup. While the Vertex measures multiple pieces, the operator completes other quality/inspection tasks. When the inspection program is complete, the operator can quickly review toleranced and exported features in a summary window. If needed, the operator can edit tools from the multi-capture cache of images.

Tools can be reviewed and edited even after parts have been removed from the stage. When the company expanded, it purchased a second Vertex. InSpec's lighting calibration ensures that programs from one machine can run on another. Also, the system price with the 2-port touch probe kit, didn't require a VP's signature. Micro-Vu Corporation was established in 1959 and is a leading manufacturer of optical comparators, video systems, and multi-sensor measurement systems. Micro-Vu machines are designed, manufactured, and assembled in the United States.

Micro-Vu Corporation http://www.microvu.com [email protected] 707-838-6272

FLEXIBLE MANUFACTURING SUPPORT manufacturing line, showed how a Helix solution could be successfully implemented using only one-third the number of sensors previously required. Helix also offers the world’s only sensors with Intelligent Illumination™ - a breakthrough technology which allows the user to choose the number, density, and orientation of the laser lines… on a feature-by-feature basis… without ever moving the sensor. The customer can create tightly spaced laser lines for small, complex features, alter the orientation of the laser lines to accommodate difToday’s manufacturing processes must successfully support a mul-

ferences between models, or increase the number of lines to handle

titude of options. High model mixes, complex product combinations,

challenging materials and substrates.

and unique short-run parts push traditional metrology systems to

The combination of Intelligent Illumination™ and expansive sensor

their limits. Perceptron’s new Helix 3D metrology solution represents

measurement volumes makes Perceptron’s new Helix 3D solution an

a quantum leap in flexible manufacturing support. Expansive sensor

innovative breakthrough in the world of 3D metrology.

measurement volumes allow customers to successfully implement comprehensive quality control strategies on even the most demand-

A Quantum Leap in 3D Metrology

ing manufacturing processes. Furthermore, the ability to support high model mixes with a simple, multi-sensor configuration allows for increased 3D measurement content while simultaneously reducing overall system cost, cycle time, and complexity. Low sensor counts and the reduction or elimination of robotic requirements make Helix a powerful and extremely economical metrology solution. One specific project, where previously over 120 sensors were

www.perceptron.com/helix

required to handle three separate models being run down the same

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63

2011 CASE STUDIES

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Increasing Metrology throughput without compromising quality

Within the custom manufacturing industry each job presents new challenges and every application requires special attention to detail. There does seem to remain one constant however… “Deliver highest quality parts at lowest possible cost”. To achieve this goal, companies continue to develop their metrology capabilities looking to achieve faster inspections without sacrificing the quality assurances delivered to their customers. Vision-based measuring systems are a key component in achieving quality-control productivity as vision-based systems typically surpass contact metrology alternatives in speed and throughput, while maintaining precision and capturing comprehensive data. Additionally, vision metrology systems eliminate potential part damage from contact inspection. The new Fetura® Vision Metrology Systems from Qioptiq represent a vanguard approach to optical measurement, combining years of optomechanical expertise with cutting-edge software and robust mechanics to deliver unparalleled productivity, flexibility, and precision. At the heart of the system is the market’s fastest and most precise zoom imaging lens technology. Nearly 10-times faster than conventional zoom lenses across a 12.5X optical zoom range, Fetura images from low to high magnification in less than 1-second (approaching that of digital zoom speeds). This important feature affords users the ability to perform critical quality inspections in shorter cycle times with greater

operational savings… a value they can pass on to their customers. In one particular case, a customer required 100% parts inspection of a high-volume medical components process. Metrology speed and accuracy gains were a necessity in achieving maximum throughput and ultimately greater quality and net productivity. The Fetura System’s imaging agility and high-speed mechanics, combined with multi-part fixturing readily achieved the customer’s aggressive inspection throughput and productivity goals. In this case, each individual component required measurements to be taken at multiple magnifications. With the Fetura’s unmatched imaging speed, the customer reduced their inspection time for each lot by more than 8 minutes. This translated to 33% more parts inspected per shift and ultimately more than $31,000 projected savings in the first year of production in inspection costs alone. This increased speed at inspection also means savings across the complete manufacturing process. In addition to its unmatched speed, the unique design of the Fetura’s imaging lens enables it to maintain optomechanical precision over 1 million zoom cycles with virtually zero performance degradation. This means prolonged and consistent precision and accuracy over the extreme rigors of a high-volume inspection application like the medical components case cited above, without the need for recalibration and uncertain software compensations. The Fetura Vision Metrology System is a robust measurement workhorse that meets the needs of demanding global manufacturing markets. The Fetura Vision Metrology Systems offer an alternative in the metrology industry that is measurably different. Article and images by: Thomas Goundry Metrology Product Manager Qioptiq, Inc. www.qioptiq.com 585-223-2370

SAVE $$$$$$: Let us “REMANUFACTURE” your SCHERR-TUMICO 30” Comparator for a fraction of the cost of a new one assemblies for profile and surface illumination, new protractor ring with digital readout Q axis in DRO, new glass screen, new curtains, replace all required lenses in the lamphouse and replace all electrical components as required. The remanufactured 2500/2600 unit is as new--it cannot be distinguished from a new unit. REMANUFACTURED COMPARATOR AND DRO CATALOG NO. DESCRIPTION 21-2600-01 REMANUFACTURED 21-2600-02 REMANUFACTURED 21-2600-03 REMANUFACTURED 21-2600-05 REMANUFACTURED 21-2800-01 REMANUFACTURED

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Left: Actual photo of customer’s 26 year old 2600 Series 30" Comparator when received at S-T Industries to be remanufactured. Right: Actual photo of the same 2600 Series 30" Comparator after being remanufactured at S-T Industries, ready to ship back to the customer. When S-T Industries remanufactures your 2600 Series 30" Comparator, it is returned to you in “As New Condition” with a certifi cate to NIST. The remanufactured price includes installation and training at your facility and a new 2-year warranty. A complete 2500/2600 remanufacture consists of the following: We completely strip down the unit, repair any damage to the body, enlarge the side door to current specs, and totally repaint the body to current paint specs. Rebuild the entire stage assembly, regrind or replace the table top and bearing ways, install new bearings, new .00005"/.001mm Acu-Rite glass scales, new bellows, new surface illuminator assembly, new long-life tungsten halogen bulb

64


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301 Armstrong Blvd. North | St. James, MN 56081-0517 Phone: 1-800-326-2039 | (507) 375-3211 | FAX 507-375-4503 [email protected] | www.stindustries.com

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QUALITY

PRODUCTS THE LATEST PRODUCTS TO HELP YOU IMPROVE YOUR MANUFACTURING PROCESS

DIGITAL MEASURING MACHINE Snap, a full function benchtop digital measuring machine, has a digital megapixel camera with native video image processing that provides high-definition video images with up to 50:1 sub-pixel resolution. Six digital zoom positions provide zoom anywhere capability, letting operators zoom in on any portion of the image to measure small part details without moving the part. The unit comes equipped with Measure-X 2D metrology software, which provides a full range of feature measurements, with no limit on the number of points or measurement steps in any routine. The unit can measure anything in its 78 millimeter field of view and its advanced telecentric optics keep parts in focus. With 75 millimeter vertical stage adjustment, parts up to 100 millimeter tall can be measured. QUALITY VISION INTERNATIONAL | (585) 544-0450 | WWW.QVII.COM

HARDNESS TESTER VISION, OPTICAL SYSTEMS WITH TOUCH-SCREEN INTERFACES Benchtop optical systems are now available with the MetLogix M2 Touchscreen Control and the the company’s EZ manual vision systems can be equipped with MetLogix M3 Touchscreen Control. The M2 and M3 iconbased touchscreen interface give operators the ability to display graphic-rich measurement data. A Windows 7-based operating system enables flexible data export and interface with Windows applications. The M2 provides instant information on feature form, tolerances and measurement data. It can coordinate display for X and Y axes and Q radius values for screen rotation. The video-based M3 is multitouch software that can pan and zoom with the touch of a finger. It works with active part views and live video feeds, as well as a conventional mouse interface. THE L.S. STARRETT CO. | (978) 249-3551 | WWW.STARRETT.COM

PHASED ARRAY FLAW DETECTOR

By combining an intuitive user interface, custom-designed optics, USB data communication, LED illumination, six turret positions and integrated digital camera, the MicroMet 6000 Series establishes a new class of dead-weight micro-indentation Vickers/Knoop hardness testers. Used for quality control and metallurgical research with dead-weight loads from 0.01 to 1.0 kilogram, the system also features a 2 kilogram option. Calibration certificates for the tester, test-blocks (provided) and indenter conform to all internationally recognized microhardness testing standards. BUEHLER (847) 295-6500 WWW.BUEHLER.COM

SPC SOFTWARE

The OmniScan MX2 phased array flaw detector features an entirely new design with a large, bright 10.4-inch LCD touch-screen that provides simple navigation, enhanced text input functionality and easy operation of parameter settings. In combination with new software features, high-capacity data storage and fast data transfer, the unit provides inspection capabilities for manual and automated phased array applications. The unit comes with all software options including Multigroup, Time-of-Flight Diffraction (TOFD) and the new Weld Overlay Wizard software that facilitates the creation of industry standard weld overlays for analysis assistance and volumetric flaw placement.

Built on Microsoft.NET, Synergy 3000 3.1 has new features including, a new Scorecard report that enables users to instantly get a snapshot of their vital production metrics for up to six characteristics. Videos related to the production can now be viewed within the application. Users now have the ability to define an often-referenced file as a hyperlink for one-click access to documents, images, Web sites or other software applications that are pertain to the product. To view more information about a specific data point, users can simply rollover it with their mouse.

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QUALITY MANAGEMENT MODULE UPGRADE An upgrade to the quality management module of Entropy Software embeds good practice quality guidelines into every facet of their quality management program. The enhancement provides improved transparency across a product’s lifecycle, facilitating the early identification of gaps in the product realization process and equipping organizations to improve business processes and drive business growth. Benefits include a system that follows product lifecycle and realization, tracking compliance to source; instant executive visibility on enterprisewide compliance to quality measurements; focused reports using traffic-light, real-time performance dashboards; ability to drive quality improvements through the supply chain; and consistency of data across business sites and comparability of internal and external assessments.

VIDEO BORESCOPE The SnakeScope video borescope is portable, handheld and can snake through areas as small as 5.5 millimeters. The unit has a choice of three different diameters and lengths to reach any application. A high-resolution 720 x 525 pixel imager provides clear images. The unit is water-resistant, and a flexible gooseneck shaft allows viewing around corners. Four adjustable LED lights illuminate the area being inspected, and still images and video can be recorded on the removable SD memory card. The unit operates on standard AA batteries for four to six hours of continuous operation. ADVANCED INSPECTION TECHNOLOGIES (321) 610-8977 WWW.AITPRODUCTS.COM

BSI GROUP (800) 862-4977 WWW.BSIGROUP.COM

SOFTWARE FOR DATA COLLECTORS ASI Datamyte has released version 1.5, which provides several new features and functions that enhance the performance of its Model 600 Handheld Data Collectors, as well as the TranSend II utility software that facilitates data transfer between data collectors and other applications. The new release reduces end user labor requirements, increases error proofing and improves data analysis and reporting capabilities. With the upgrade, three new SPC reports—x-bar and range, x-bar and sigma, and a histogram—are dispatched directly to the 600’s highresolution, color screen, allowing operators to see the results of their data collection efforts analyzed and displayed in real time. In addition, the view key can now be configured to bypass the intermediary menu and allow operators to go directly to the chart or table they want with a single key stroke. The TranSend II setup editor supports entry of control limits, so alarms can be set to trigger on violations of XUCL, XLCL, RUCL and/or sUCL.

OPTICAL TABLE ISOLATION SUPPORT SYSTEM

NONCONTACT TUBE INSPECTION SYSTEMS

Due to its Minus K negative-stiffness technology, the MK52 optical table isolation support system achieves low net vertical natural frequency without limiting its ability to support static loads. Horizontal isolation is provided by beam columns connected in series with the vertical-motion isolator. When adjusted to a ½ hertz natural frequency, the unit achieves 93% isolation efficiency at 2 hertz, 99% at 5 hertz, and 99.7% at 10 hertz. The system can be configured for a variety of locations and applications, wherever external vibrations can adversely affect the operation of sensitive equipment. The unit is available in table sizes up to 4 feet x 8 feet with gross load capacities up to 2,000 pounds. Tables are constructed with a 3⁄16 -inch thick ferromagnetic stainless steel top skin, 3⁄16 -inch thick carbon steel bottom skin, and plated-steel precision honeycomb core.

The new line of noncontact tube inspection systems provides solutions for an array of tube and wire bending applications including tube inspection, bend correction to reduce scrap, reverse engineering and fixture verification. A range of noncontact, infrared probes provide operator-assisted visual notification via a laser stripe indicating the measured area. The operator can view where data points are acquired on a tube or wire during the inspection process. The probes are interchangeable with traditional ball probes without the need for re-calibration, delilvering plug-and-play capability. Brackets, flanges, bosses or other geometric features can now be included in the measurement routine. The noncontact probing feature enables measurement of the most flexible tubes or wires from 4 millimeters to 130 millimeter in diameter, without risk of deflection.

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69

y t i l a u Q t n a W

e r mo

x? o b r in u o try y s u o t d n of i ctly s e d r n i rs, a d e s t u t d o e l e h ws e he t ver t i N l f s e o e d e ty w i n l e o a y u en / eQ ead r h l t a m g t o no vin c i . e e r ’ g c u e a sr l m If yo a y n t o i l s si a e f u o r q p w. w w ay! t d i o s t i v cribe s b u and s

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ADVERTISING INDEX ADVERTISER

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Accelper Consulting

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American Society for Nondestructive Testing

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7

www.mark-10.com

Phone: (856) 358-4800

Marposs Corp.

11

www.marposs.com/MakeSense

FAX: (856) 358-0900

Micro-Vu

23

www.microvu.com

[email protected]

Mitutoyo America Corp.

IFC

www.mitutoyo.com

NSF International

27

www.nsf-isr.org

Origin Technologies Corp.

10

ww.origintech.com

Perceptron

47

www.perceptron.com/helix

Qioptiq Linos Inc.

14

www.qioptiq.com

Renishaw

29

www.renishaw.com

CENTRAL AND SOUTHEAST

Bill DeYoe 109 Willow Springs Trail Mt. Holly, NC 28120 Phone: (704) 822-6434 FAX: (704) 822-6834 [email protected]

Scienscope

33

www.scienscope.com

Shimadzu Scientific Instrument

13

www.ssi.shimadzu.com/testing

Starrett Co., The L.S. MIDWEST, SOUTHWEST,

S-T Industries Inc.

WEST AND NORTHWEST

Sturtevant Richmont

Buck Bicek 5820 Middaugh Ave.

Sun-Tec Corp. UBM Canon

3, 32

www.starrett.com

9

www.stindustries.com

26

www.srtorque.com

45

www.suntechcorp.com

IBC

www.qualityexpo.com

50

www.unitedtesting.com

Downers Grove, IL 60516 Phone: (630) 971-0904 FAX: (248) 502-1086 [email protected]

INSIDE SALES INSIDE SALES MANAGER

United Testing Verisurf

25

www.verisurf.com

Webster Instrument Inc.

34

www.webstertesters.com

Western Gage Corp.

45

www.westerngage.com

Wilson

42

www.wilson-hardness.com

Yxlon International

51

www.yxlon.com

This index is provided as a reader service. The publisher assumes no liability for errors or omissions.

Sunny Coverly 116 Cooper Ln. Oxford, PA 19363 Phone: (610) 932-8350 FAX: (248) 283-6587 [email protected]

72


QUALITY (ISSN 0360-9936) is published 13 times annually, monthly except semi monthly in November, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: QUALITY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to QUALITY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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August 2011

DEPARTMENTS Source: Intelligent Optical Systems

4NDT

Editor’s Note

COMPUTED TOMOGRAPHY

5NDT

8NDT

15NDT Tech Showcase

Computed Tomography— The CAT’s Meow

The Rules of X-Ray Micro CT Better understanding the rules of X-ray micro CT not only opens the door to production cost savings and productivity improvement, but also knowing when to break them can provide even further process flexibility.

Industry News Ultrasonics

24NDT Products IBCNDT Advertising Index

THERMOGRAPHY

12NDT Thermography of Turbine Airfoils Until recently, thermography was limited to a secondary, qualitative role in airfoil QA. However, advances in the technology have given rise to thermographic QA systems that are capable of replacing traditional technologies.

IN THE NEXT ISSUE NDT Lab Services Remote Visual Inspection

LEAK TESTING

16NDT Integrating Leak Testing in Automated Assembly and Test Production Systems The right leak testing method will help avoid the unnecessary costs of adding material and labor to fix defective production components.

LASER ULTRASONICS

20NDT Laser Ultrasonics –The Next Big Nondestructive Inspection Technology? Laser Ultrasonics may not quite be the buzz word in nondestructive testing yet, but a handful of industries have recognized its benefits and have implemented a laser ultrasonic system to good effect.

Hardness Testing

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ABOUT THE COVER High-accuracy X-ray micro CT technology continues to evolve and its applications are diverse and growing across the automotive, aerospace, energy, medical, electronics, and electronics packaging sectors. Source: Photos.com Source: InterTech Development Company 2 NDT ● AUGUST 2011

NDT SPECIAL SECTION

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Computed Tomography— The CAT’s Meow There is no doubt that just about everyone in the field is familiar with computed tomography as a non-destructive technology. Most everyone else is familiar with it as it pertains to health care, having at the least heard of a CT scan, sometimes referred to as a CAT scan.

Darryl Seland Editor in Chief [email protected]

4 NDT ● AUGUST 2011

R

Recently, N Newswise reported that researchers from UCL UCLA and the University of California completed a ten-year clinical study of 53,000 current or heavy smokers that concluded that those who wh were screened with low-dose spiral CT scann scanning had a 20 percent reduction in deaths from lung cancer apposed to those who were screened by chest X-ray. According to the reporting, the study—called the National Lung Screening Trial (NLST)— was conducted among this high-risk group to compare the differences in death rates for lung cancer between those who were screened annually with low-dose helical (or spiral) CT versus the conventional chest X-ray. The study was published in the June 29th online edition of the New England Journal of Medicine. Dr. Denise R. Aberle, a principal investigator for the NLST and a researcher with UCLA’s Jonsson Comprehensive Cancer Center, said the publication of the study offers further definitive evidence of a significant mortality benefit from CT screening. “These findings confirm that low dose CT screening can decrease deaths from lung cancer, which is expected to kill more than 150,000 Americans this year alone,” said Aberle, who serves as vice chair for research in the Department of Radiological Sciences. “This study also will provide us with a road map for public policy development in terms of lung cancer screening in the years to come.” Aberle also commented that while the study cannot answer all the questions regarding implementation, “the NLST data can be used to develop mathematical models to determine how long screening should be performed and how often” and “can be used to determine whether other groups at risk of lung cancer,

NDT SPECIAL SECTION

such as light smokers, those with family histories of lung cancer or individuals with lung diseases like emphysema, would benefit from screening with spiral CT scanning.” CT technology in the medical field can be traced back to the early 1900s with Italian radiologist Alessandro Vallebona’s method for representing a single slice of the body on the radiographic film known as tomography. It is based on projective geometry—“moving synchronously and in opposite directions the X-ray tube and the film, which are connected together by a rod whose pivot point is the focus; the image created by the points on the focal plane appears sharper, while the images of the other points annihilate as noise. In the late 1970s, “minicomputers” and of the transverse axial scanning method developed by Godfrey Hounsfield and Allan McLeod Cormack moved the technology to “computed” tomography. This improved method took 180 separate readings every 1° with each scan taking a little more than five minutes. A large computer then reconstructs the images using algebraic equations…just like my tenth-grade math teacher warned me. While its success in the medical community is credited with saving countless lives, its benefits in the non-destructive technology field are also well established. Gain a better understanding of the rules of X-ray micro CT, not only opens the door to production cost savings and productivity improvement, but also knowing when to break them can provide even further process flexibility in this month’s feature article, “The Rules of X-Ray Micro CT (and When to Break Them),” by Andrew Ramsey. Enjoy and thanks for reading! www.ndtmag.com

NDT Industry Survey Points to Job Growth ARLINGTON, MA—In a recent survey by nondestructive testing (NDT) networking company PQNDT, the company asked a series of supplemental questions about layoffs and unemployment in the NDT industry. Overall, 7.5% of those surveyed had lost their jobs in the previous 12 months. The rate remained below the national unemployment rate, which hovered around 10% for much of the year, and is still above 9%. PQNDT gathered its data in 2010, while the country was still in recession. Of those laid off, most (70%) had found new jobs, and most of those found new employment fairly quickly (82% within four months). During the first half of 2011, there was a jump in the number of contract NDT

assignments. This is an indication of an increasing workload, tempered with caution about hiring permanent, full-time employees. That trend is now shifting over to more companies looking to hire for full-time permanent NDT positions, as the economic recovery begins to take more solid hold, according to the survey. For full survey results, visit www. pqndt.com/resources.html

AcousticEye Inks Partnership with NDT Company Sound Tube Testing MILAN, ITALY—AcousticEye, the leader in non-invasive tube inspection solutions for the heat exchanger market, has signed a strategic agreement with nondestruc-

tive testing (NDT) company Sound Tube Testing, based in the Netherlands. Sound will deploy the AcousticEye Dolphin G3 systems throughout Europe, making the tube inspection technology readily available to the region. The two companies made the announcement at POWERGEN Europe, where they are exhibiting together at Booth 5D46. “With this partnership in place, we expect the penetration of our ultrafast inspection system into Europe to accelerate greatly,” says Brenda Zeitlin, vice president of Business Development for AcousticEye. “Under the agreement with Sound we can already boast the entrance of the Dolphin G3 into the markets in Germany, Greece, Croatia, Spain and Benelux.”

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NDT SPECIAL SECTION

AUGUST 2011 ● 5 NDT

Sound Tube Testing has already signed on five new service providers in Europe, representing new territories for AcousticEye. The providers are: Vogt Ultrasonics GmbH in Germany, Technava S.A. in Greece, Trokuttest d.o.o. in Croatia, DiagnostiQA Consultoria Tecnica S.L. in Spain, and HPFM in the Benelux region.

With many more prospects in the pipeline, the AcousticEye APR technology is guaranteed to be widely available for the inspection of all heat exchangers throughout Europe. “Our company has been very impressed with AcousticEye’s technology since we first started using it last year, and we are

Quickly find burrs and other defects!

excited about the prospect and opportunity to make this inspection technology available throughout Europe,” says Hans Felius, CEO of Sound Tube Testing.

Professional Aviation Associates Forms an Alliance with Accessory Overhaul Group ATLANTA, GA– Professional Aviation Associates, a Greenwich AeroGroup company, has formed an alliance with Accessory Overhaul Group Inc. (AOG Atlanta). With facilities in Griffin, GA, and Phoenix, AZ, A.O.G. Inc. is an FAA/EASA-certified repair station, accessory class I electrical accessories, class II electrical accessories and class III electronic accessories. A.O.G. specializes in aircraft component testing, overhauling and certification services including brakes and wheels, starters and generators, batteries, nondestructive testing and aircraft beacon testing and overhaul. “We are combining our sales staff and inventories with A.O.G.’s shop capabilities and mobile on-site NDT services, meaning we can now offer a more comprehensive realm of services,” says president of Professional Aviation Associates Glenn MacDonald. “This venture will also provide us with the ability to continue to innovate and grow in the rotorcraft and fixed wing markets, which will benefit current and future customers worldwide.” Professional Aviation Associates has sales offices in Atlanta, GA, and London, England.

Seland Joins Quality Magazine as Editor in Chief Made in USA

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NDT SPECIAL SECTION

DEERFIELD, IL—BNP Media announces that Darryl Seland has joined Quality Magazine as its new editor in chief. He will work out of the company’s office in West Chester, PA. Seland brings more than ten years of experience in trade magazine publishing having worked for magazines covering the financial sector and construction and heavy equipment markets. Most recently, Seland served as editor in chief and associate publisher for another of the company’s titles, CircuiTree, a magazine devoted to the printed circuit board www.ndtmag.com

industry. Seland also holds an MBA and a bachelor’s degree in journalism. In his new role, Seland will take over responsibilities for Quality’s Vision & Sensors and NDT magazines, as well as provide direction and leadership for the breadth of Quality Magazines’ offerings to its readers. “I look forward to the opportunity and to covering this very innovative market,” says Seland. “Like the metrology and quality inspection industries themselves, Quality magazine is about innovation. We will continue to not only deliver the information its readers want and need, but also deliver it in an innovative way, whether through print, digital editions, eNewsletters and online.”

NDT Systems Celebrates 40th Year with Move to New Facility HUNTINGTON BEACH, CA— NDT Systems Inc. has relocated to a cus-

tomized facility three times the size and blocks away from its former facility in Huntington Beach, CA. The move coincides with NDT’s 40th year in business. NDT Systems was incorporated April 28, 1971, by Founder Ron Basko, a wellknown figure in the American Society for Non-Destructive Testing (ASNT), and credited with many innovations in the field. From the start, the company’s charter has been to develop, manufacture and market a comprehensive line of ultrasonic transducers and imaging devices. After 18 years of growth, the company was acquired by E.I. DuPont in 1989. DuPont sold the business in 1993 to a private investor involved with medical imaging. In 2000, the business was reacquired by Greg Smith, an engineer, inventor and long-time employee of the company. As the new president and CEO, Smith renewed NDT Systems’ com-

W R2 NE FO TS

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mitment to lead the field by improving and expanding the company’s line of non-destructive testing instruments and technology. Having outgrown its previous building, the roomier new facility creates an environment designed to stimulate and accommodate continued growth. Visitors are welcomed by an artistically designed and inviting reception area. A 700-square-foot meeting room is equipped for video conferencing and Internet access and the entire facility is wired as a proprietary Wi-Fi hot spot, providing building-wide access to locally hosted online sales and training tools. Office space has increased 2,000 square feet and manufacturing floor space has doubled. Because of the high-tech nature of the industry, and in response to the critical requirements of its customers, the company is under contract to earn ISO certification for the new building and its personnel.

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The Rules of

X-Ray Micro (AND WHEN TO Better understanding the rules of X-ray micro CT not only opens the door to production cost savings and productivity improvement, but also knowing when to break them can provide even further process flexibility. By Andrew Ramsey Offer the term “metrology equipment” to a group Offe industrial or manufacturing engineers in a of in word-association test and it’s highly likely CMM word (coordinate measuring machine) would be the (coor coor response. Yet, unlike a probe-based measuring respo espo methodology, X-ray micro computed tomography meth (μCT) not only has the accuracy, resolu(μC (μCT tion, speed and flexibility manufacturers require, it provides details and insight unattainable by other means (think porosity and density mapping, for example). High-accuracy X-ray micro CT technology continues to evolve. Applications are diverse and growing across the automotive, aerospace, energy, medical, electronics and electronics packaging sectors, dealing with metals, exotic alloys, composites and single-crystal materials. Accompanying software tools enable the analysis of part volume against the CAD model, either via direct volume-to-CAD comparisons or through geometric dimensioning and tolerance measurements. And

O 8 NDT ● AUGUST 2011

NDT SPECIAL SECTION

with price points low enough to make it competitive with other techniques, X-ray micro CT is ready for the metrology mainstream. Better understanding the rules of X-ray micro CT not only opens the door to production cost savings and productivity improvement, but also knowing when to break them can provide even further process flexibility. Claims are made that CT is only appropriate for light metals, plastics or objects of limited size, when the reality is that such limitations may belong only to those making the claims. Better understanding the rules of CT certainly provides a better basis for what is possible with this technology.

The Basics X-rays are at the short end of the electromagnetic spectrum with an average wavelength between 10 -8 and 10 -12 meters, around the size of water molecules, compared to radio waves with wavelengths that could span a soccer field. There are no radioactive sources in X-ray micro CT; rather electrons are produced from a hot filament similar to a light bulb and accelerated at high voltage, creating a beam of electrons reaching speeds up to 80 percent of the speed of light. The electron beam is focused by a magnetic lens onto a metal target, producing a spot typically between 1-5 μm in diameter. The sudden deceleration of the charged electrons when they hit the metal target produces 99.03 percent heat and 0.7 percent X-rays. These X-rays emanate from the region where the electron beam hits the target. The size of this www.ndtmag.com

CT BREAK THEM)

A minifocus source (around 1 mm) allows no magnification, whereas a microfocus source (1-5 μ) can be magnified to produce higher-resolution images. Source: Nikon Metrology Inc.

spot is referred to as the X-ray spot size. In general, the higher the voltage applied, the more power is in the beam, and consequently, more power is transferred to the target. The more power on the target, the larger the X-ray spot size and the more X-ray power produced. X-rays travel in a straight line, through the object being inspected, and onto a detector. The object will absorb some of the X-rays (denser objects absorbing more), leaving only a portion to reach the detector. At low X-ray energies (

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