Quality October 2011

OCTOBER 2011, VOLUME 50/NUMBER 10 WWW.QUALITYMAG.COM

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TABLE OF

CONTENTS QUALITY MAGAZINE

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OCTOBER 2011

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VOLUME 50

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NUMBER 10

DEPARTMENTS

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FROM THE EDITOR

The Big Five-O 10 INDUSTRY NEWS

Noncontact Probing Technology to Lift Sales Ford, Honda, Chrysler Launch Big Recalls Ford and Honda to Collaborate on Hybrid Technology

FEATURES 50 YEARS OF QUALITY

28 UNIVERSAL TESTERS THROUGH THE YEARS There are many types of testing machines. The most common are universal testing machines, which test materials in tension, compression or bending. This month 50 Years of Quality takes another look at universal testers.

QUALITY MEASUREMENT

32 AIR GAGING FOR ORTHOPEDIC DEVICES Air gaging has become the inspection tool of choice for controlling critical parameters in the medical industry.

QUALITY TEST & INSPECTION

36 THE CALIBRATION AND ACCURACY OF X-RAY CT SYSTEMS X-ray CT systems must be traceably calibrated to give true metrological performance.

QUALITY MANAGEMENT

40 THE LASTING LEGACY OF THE MODERN QUALITY GIANTS As Quality Magazine celebrates its 50th anniversary, we take a look at some of the quality gurus who have made a significant impact on the world through their contributions to improving not only businesses, but all organizations.

48 CALIBRATION CAN BE RISKY BUSINESS When it comes to calibration requirements, make sure you get what you need.

20 FACE OF QUALITY

Continuous Improvement is a Team Effort 21 OTHER DIMENSIONS

Calibration: You Get What You Pay For 22 QUALITY 101

Understand Coating Thickness Measurement Test Methods 26 QUALITY INNOVATIONS

Not Lost in Translation 52 CASE STUDY

Software Removes the Human Error Element 70 QUALITY PRODUCTS 71 CLASSIFIEDS 72 ADVERTISING INDEX

NEXT MONTH Video Measurement CMMs Certification/Registration CAD Software

OCTOBER 2011, VOLUME 50/NUMBER 10 WWW.QUALITYMAG.COM

ABOUT THE COVER Quality Magazine celebrates 50 years of providing manufacturers with information on its greatest asset—quality. Source: Quality Magazine

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QUALITY | October 2011

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YOUR

A DVA NTA G E

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INNOVAT ION

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IN FORCE MEASUREMENT Introducing the latest innovation in force measurement - the Starrett FMS Series. It incorporates new performance-based capabilities and user-friendly features to help you perform critical force [LZ[Z^P[ONYLH[LYHJJ\YHJ`HUKLMÄJPLUJ`0[»ZZVWOPZ[PJH[LKLUV\NOMVYKLTHUKPUN8*HWWSPJH[PVUZ but also durable enough for high-volume production shop environments. It can perform all of your IHZPJMVYJLTLHZ\YLTLU[[LZ[ZHZ^LSSHZTVYLJVTWSL_T\S[PZ[HNL[LZ[Z[VPU[LYUH[PVUHSZ[HUKHYKZ ;OL-4::LYPLZPZH]HPSHISLPUMV\YJHWHJP[PLZ!5R5R5HUKR5 So, if you’re looking for what’s next in force measurement, start your search with Starrett.

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

Available On-Demand Basics of Torque Testing Torque measurements are used by manufacturers to determine good assembly from bad. Science Needs to Work Smarter The U.S. and other leading nations are looking to science and technology advancements to spur economic security and growth. Meanwhile, the political season has prompted fierce debates over the return on investment in research and the role of science in shaping public policy. Never before, it seems, has science held such contrasting, controversial and conflicting roles in the national conversation. Quality Revolution Reduces Defects, Drives Sales Growth at 3M By combining Lean Six Sigma and a top-200 customer focus, 3M improved its belt fabrication processes. The improvement team reduced defects in parts per million by a factor of 28 times as sales increased by 54%.

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

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.

• 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.

NOW PLAYING ON Q-CAST

NOW PLAYING ON Q-TUBE

The Importance of ISO 50001

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

Calibration Management Software: Important Factors Manufacturers Need to Know AS 9100 Revision C–What You Need to Know The Importance of SPC to Quality Management Systems

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QUALITY | October 2011

Paul Jr. Designs Paul Jr. Designs looks for the latest technology to advance the level of customization it can provide to its customers.

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Precision is Our Business.

“Let it be said: ‘It was done right, it was done well.’ Perfection must be your credo of work and quality your way of life.” KONSTANTIN

THIS WE BELIEVE:

With the eyes of millions of people glued to TV screens watching a space capsule take-off, one thought crowds out all others … will it work? And when the astronaut is fished from the ocean, one fear is uppermost … what if the cable snaps? The prayer and hope that the thing and all its parts will work is the culmination of many long nights of work; the finale to a monumental formula of quality assurance, men, and natural laws. By the innocent phrase, “will it work?”, dangles life—and liberty. Though our space program is dramatic and new, don’t the same fears and questions apply to jet planes, automobiles and trains? But here we do not ask, “Are we safe to entrust our life and limbs to the quality of these assorted pieces of metal, electromechanical systems and components?” There is a blithe and justifiable assumption that the things will work. What of the garden-variety of products: castings, bearings, switches, bolts; and the myriad of pure consumer items, such as refrigerators, bicycles, radios and furnaces? Who is to say their quality is not vital? Here is also an inherent dramatic situation. Nothing which America’s ingenuity and hard work produces is unimportant. Is the quality of missiles and aircraft a far cry from more mundane products? Not from the standpoint of over-all economic life. A manufacturer may lose a sale due to lengthy delivery, wretched service or high price. But he should never fail of the order because of second-best quality. This is true whether meeting domestic or overseas competition. Quality is a manufacturer’s greatest asset. With it, sales can be increased; without it, the profit squeeze becomes a strangling python. Unfortunately, some managements, caught in the cost/profit vise, will chisel on the quality of their products to effect economies. “It’ll do,” they say. The theory of “good enough” neither builds rockets, bridges nor a sound business. Profits are made by selling more and better products. To be sure, an effective quality assurance department will effect economies by reducing scrap, preventing premature failures and eliminating receipt of faulty incoming material and components. However, as the quality of a product undergoes tampering, every phase of the benefits of a quality assurance program is minimized. A business can thus hack up a program into minor bits and pieces. All junk! We believe a quality assurance program will increase sales of a better product, will stimulate sound economies in the manufacturing cycle, and will permit a business to meet overseas competition with a resounding whack on the head. Another reason for the importance of quality lies in the technological improvements of the past few years. Closer tolerances; customer insistence on rigorous inspection before shipping; higher warranty demands by purchasers; more trying service conditions under which products must perform; finer finishes; and the development of predictability and reliability techniques have tugged at industry’s coat tail, causing them to stop and look at industry’s fastest growing and most important profession: quality assurance. What of management in relation to quality assurance? If rockets, missiles, aircraft, autos, profits and sales; if our very life and limbs, and in a broader sense, our liberties, depend on quality – what of management in whose hands final authority rests? Quality is management’s job! Not on a part-time basis—but completely and absolutely! From the very top of the managerial pyramid the sense of quality must penetrate into every department, into every office, into every corner of the plant. Quality must become, for management executives, a way of living … a manner of thinking.

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quality assurance

… a statement of objectives Some executives turn the quality assurance function over to production or engineering. To them, quality is still the lone inspector—a rather necessary evil who tries to hold down the scrap. The full implications of quality assurance, so far removed from the solitary checker of ten years ago, are not yet appreciated. This is not unnatural. Blame must be tempered with the observation that the fantastic growth of the quality assurance discipline—having received adrenalin from the space programs—has been so rapid and so overwhelming in its impact that many executives have not yet caught up. If quality is so vital to America’s safety, progress and economic health, what of the star performers in this drama: the quality assurance professionals? Their gages, systems, chambers, switches, lights and mathematics spell out success or failure. On their knowledge, imagination and dedication hangs a life. Here, then, is a function of industry which safeguards our national prestige, prevents loss of life and limb, reduces costs, meets competition, and increases sales. This army of professionals (one out of every ten production workers is engaged in a quality assurance function), charged with such responsibilities, is important indeed! These are no longer men of some minor and barely-to-be-tolerated department in a dark corner … although in some industries they still perspire under heavy handicaps. The growth of the quality assurance profession, embracing reliability and predictability, may be misdirected. Its strength and capability may become a serious weakness. The idea that something can be designed, built and so tested that the service life of the product can be accurately determined could lead many industries into a program of planned obsolescence. To manufacture a product which will last exactly so many years and so many months, at which time the user must replace it, defeats the very principle of quality and vitiates the essence of a quality assurance program. A planned obsolescence program must be opposed by all means. No lasting benefit can come from it. In conclusion, quality assurance believes: …nothing is more important to America than the quality of its products; …a sound quality assurance program increases efficiency, decreases costs, meets competition, increases sales and reduces the profit squeeze; …quality is management’s concern, with which it must live, think and sleep. From management it must permeate every corner of the plant; …quality assurance people are the fastest growing group of professionals in industry—and none in industry is more important. To unify all aspects of quality assurance; to broaden knowledge and understanding of management and quality assurance professionals; to continually reiterate the importance of quality to America, to oppose any perversion of the quality assurance function; and to continually champion new techniques, greater efforts, and always superior products … to these ends we dedicate this volume 1, number 1, and all subsequent issues of quality assurance. W.F. SCHLEICHER Publisher and Editor Reprinted from the inaugural issue of Quality Assurance, October 1962

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October 2011 | QUALITY

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FROM THE EDITOR

THE BIG FIVE-O

ACCOLADES ARE BESTOWED AS QUALITY CELEBRATES 50 YEARS.

A

BARBARA GRIM

s the senior member of the Quality staff, I asked if I could have some space in this 50th anniversary issue to offer a few “thank yous” on behalf of Quality. The very first thank you is directed to our advertisers both new and old. We all know that without advertising support there would be no Quality Magazine. Thank you! The test, measurement and inspection equipment, and software your companies have developed has improved virtually everything we own and made our lives safer. A very special thank you goes to those advertisers whose ads appeared in our first issue and continue to support us today. Throughout this issue you’ll see a special designation on their ads recognizing them as original advertisers. These companies have stood the test of time as they serve the manufacturing community with innovative products and great technology. There wouldn't be a Quality Magazine without our loyal subscribers, either. Thank you! We have worked hard to satisfy your information needs and be the cheerleader for your team. Improving the quality of manufactured goods while increasing productivity and decreasing costs is the goal of every quality professional. We salute you and strive to promote your goals. This anniversary also is a time to ref lect and offer thanks to a few of the many responsible for the "birthin'" and the "rearin'" of this great magazine. I personally worked with each of these great men and their legacies live on in what we do every day here at Quality:

Bill Schleicher Dan Reardon Loren “Chick” Walsh Dick Templeton Dutch Feldon Frank Taylor If you have a memory about any of these folks or about your history with us, I hope you’ll drop me a note at [email protected] or share your thoughts 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. And a final thanks to everyone at BNP Media who works day in and day out to provide you with the best information in ways not thought of in 1962. Personally, I’ve loved every minute that I’ve spent “bringing up” Quality.

Barbara Grim is associate publisher of Quality and serves as the regional sales manager in the mid-Atlantic and Northeast working out of an office in New Jersey. She has been with Quality since June 1980.

Editorial offices: 155 N. Pfingsten Rd., Suite 205, Deerfield, IL 60015 (248) 362-3700 • fax (847) 405-4100 • www.qualitymag.com

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QUALITY | October 2011

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Publishing: John R. Schrei Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Information Technology: Scott Krywko Clear Seas Research: Beth A. Surowiec

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COMING EVENTS NOVEMBER 8-10 [MC]^2 MTCONNECT: CONNECTING MANUFACTURING CONFERENCE Cincinnati, OH MTConnect Institute (703) 728-8885 www.MTConnect.org VISION 2011 Stuttgart, Germany Messe Stuttgart +49 711 18560-2541 www.messe-stuttgart.de 14- 17 FABTECH 2011 Fabricators & Manufacturers Association International Chicago, IL (800) 432-2832 www.fabtechexpo.com JANUARY 31 LEAN EXPERT TRAINING AND CERTIFICATION Juran Institute Clearwater, FL (800) 338-7726 www.juran.com/services_training_ public_workshops.html FEBRUARY 7 LEAN SIX SIGMA BLENDED GREEN BELT Juran Institute Charlotte, NC (800) 338-7726 www.juran.com/services_training_public_ workshops.html

PEOPLE NEWS TÜV SÜD America Inc. (Peabody, MA), a global testing, inspection and certification services firm, has appointed IAN NICOL to the role of president and CEO for Americas operations, including TÜV SÜD Canada, TÜV SÜD América de México and TÜV SÜD America do Brasil. Originally from Motherwell, Scotland, Nicol has served in numerous senior management roles in certification, inspection and testing industries worldwide. Bunting Magnetics Co. (Newton, KS) has added three new design engineers to its technical services department. MATTHEW MASON, CORY DREILING and BRANDON BOUSQUET, all recent graduates of Wichita State University, will initially concentrate on the company’s material handling product line. Sick Ltd. (Minneapolis, MN), a producer of sensors and sensor solutions for industrial applications and a factory, logistics and process automation company, has appointed CRAIG S. SMITH president of Sick Ltd. in Canada. Smith is senior leader with proven sales, marketing and operations experience in both the manufacturing and industrial automation business.

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QUALITY | October 2011

BUSINESS NEWS | COMING EVENTS | PEOPLE NEWS | MERGERS

CMMS: NONCONTACT PROBING TECHNOLOGY TO UPLIFT GLOBAL SALES LONDON, UK—The mature world coordinate measuring machine (CMM) market is slated to grow at a compound annual growth rate (CAGR) of 4.6% from 2010 to 2015, driven by pent-up demand and product introductions during the short and medium terms, says market research and consultation company Frost & Sullivan.  New analysis from Frost & Sullivan in the world coordinate measuring machine market finds that the market earned revenues of $1.43 billion in 2010 and estimates this to reach $1.79 billion in 2015.  New opportunities have unfolded as built-up demand post-recession is unleashed to energize market prospects. There is a distinct shift in the use of CMMs from quality control to process control. The use of dimensional measurement by vendors to check the process involved has contributed to the growing utilization of CMMs in process control.  Manufacturers in this domain are rolling out application-specific products that provide better ROI. These machines are custom built to cater to varying end-user requirements. The upsurge in made-to-order manufacturing has augmented revenues of application-specific machines. Vendors are increasing their focus on temperature compensation, high-speed data-gathering sensor technology and software improvements.  “For vendors in this space, the accent is on noncontact probing technology,” says Frost & Sullivan Industry Analyst Prathima Bommakanti. “Laser-based noncontact probes, which have great advantages in the

amount of data acquired and the speed with which it is obtained, are highly accepted in the automotive and aerospace industry.”  In the aftermath of the recent economic crisis, the CMM market has become highly price-sensitive. Vendors are under pressure to produce dramatic results, often while operating on shoe-string budgets. The low-end and mid-range CMM segments, in particular, are witnessing high price pressure. Major CMM end users such as aerospace, automotive and machine shops have gradually shifted from standardized production processes to custom jobs.  The automotive industry too has moved away from producing large quantities of identical engine blocks to a few thousand similar pieces, as the engine designs change every year and the vehicle models in the market have proliferated. Market participants find it challenging to keep in step with changing customer needs.  Slow replacement rates also have curbed market progression. Being robust, CMM equipment does not wear out as fast as other industrial products. Although some parts need to be replaced over time, there is often no need to buy a new machine for years. The average replacement rates for CMM can be higher than 10 to 15 years, thus affecting the sale of the new machines.  “To survive in this landscape, smaller regional suppliers must enhance awareness levels on their technologies and focus on offering better value propositions,” concludes Bommakanti. “Besides, they must expand their operations in emerging economies such as China and India, either by setting up new facilities or through individual agents.” 

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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NEWS FORD, HONDA, CHRYSLER LAUNCH BIG RECALLS DEARBORN, MI, AUBURN HILLS, MI and TOKYO—Ford Motor Co., Chrysler Group LLC and Honda Motor Co. Ltd. each announced widespanning recalls in August. The most recent was Honda with more transmission issues, the company saying it has begun a recall of 1.5 million vehicles in the United States to update automatictransmission software to help prevent damage to a secondary-shaft bearing that could be affected by rapid shifting between forward, neutral and reverse. Honda said the affected vehicles are 2005-2010 Accords with 4-cylinder engines, the 2007-2010 CR-V and 2005-2008 Element.  Ford recalled 1.2 million F-Series pickups from various series, in addition to Lincoln-badged versions of the F-150, sold in North America between 1997 and 2003 to replace what might be corroded metal straps that secure the fuel tank to the chassis.  Chrysler said it is recalling almost 300,000 2008 Chrysler Town & Coun-

try, Voyager and Dodge Grand Caravan minivans that could accidentally deploy the front air bags. 

FORD AND TOYOTA TO COLLABORATE ON HYBRID TECHNOLOGY DEARBORN, MI and TOYOTA CITY, JAPAN—Ford and Toyota, companies that both developed and marketed vehicles with full hybrid powertrains, both stated that they would collaborate to produce new hybrid systems for light trucks and sport utility vehicles.  The companies say they anticipate products in the marketplace before the end of the decade. In addition to hybrid technology, the automakers plan to work together on the development of standards for in-car telematics and Internet-based services. Currently, Ford and Toyota hybrid systems for front-drive vehicles are somewhat similar, so a joint effort seems to be a good fit. Both automakers presently make parallel systems that can operate the electric motor either independent of or in combination with

the gasoline engine, while charging the battery pack with a generator fed by the gasoline engine and through regenerative braking.  Some news sources reported Ford licensed Toyota patents when it introduced its first hybrid vehicles and that there may have been cross-licensing of patents over the years.  In a joint statement, the automakers said that they had been separately developing rear-wheel-drive hybrid powertrains, but chose to team up to bring new technology to the marketplace sooner, as well as to save development expenses, which would lead to lower costs down the line. 

J.D. POWER AND ASSOCIATES REPORTS: AUGUST NEW-VEHICLE RETAIL SELLING RATE EDGES UP FROM JULY WESTLAKE VILLAGE, CA—Newvehicle retail sales for August have yet to spark a stronger recovery, but the selling pace continues to increase slowly from its low point in May, according to J.D. Power and Associates, which

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gathers real-time transaction data from more than 8,900 retail franchisees throughout the United States.  August new-vehicle retail sales were projected to come in at 898,000 units, which represents a seasonally adjusted annualized rate (SAAR) of 9.9 million units. The retail selling rate is higher than in July, although volume remains essentially flat. Retail transactions are the most accurate measurement of true underlying consumer demand for new vehicles.  “The selling rate in August is expected to be slightly stronger than in July, but without a significant increase in incentive levels or a reversal of the economic woes, there isn’t a compelling reason for those consumers sitting on the fence to return to dealer showrooms and purchase a vehicle,” says Jeff Schuster, executive director of global forecasting at J.D. Power and Associates. “There is little question that a strong level of pent-up demand exists, but economic and financial uncertainty is keeping it from being released.”  Total light-vehicle sales in August are expected to come in at 1,074,900 units,

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which is just 4% higher than in August 2010. Like July, August is normally a low fleet month, with sales of 177,000 units expected—which is 16% of total sales. Sales Outlook  Given the recovery stall that continues to persist and lower expectations for growth in the economy, J.D. Power is lowering its forecast for light-vehicle sales in 2011 and 2012, as the slower recovery is expected to extend into next year. Total light-vehicle sales for 2011 are now expected to come in at 12.6 million units. This is still a 9% increase from 2010, but is down from the previous forecast of 12.9 million. Retail light-vehicle sales are now forecasted at 10.2 million units for 2011 (from 10.5 million).  For 2012, the outlook for total lightvehicle sales has been reduced to 14.1 million units (from 14.7 million). Retail light-vehicle sales are now at 11.5 million units (from 12 million).  “The economy and automotive industry continue to wrestle with a

series of unsettling developments, which are now likely too strong to overcome within 2011,” says John Humphrey, senior vice president of automotive operations at J.D. Power and Associates. “While it is not time to hit the panic button, it is clear that ascending from the recession is proving to be just as bumpy as the decline into it, and a full recovery in vehicle sales is further down the road than previously thought.”  North American Production  Light-vehicle production in the North American region has increased by 8% through the first seven months of 2011 from the same period in 2010, with volume of 7.3 million units. At the country level, production in Mexico is showing the strongest year-over-year change, rising 16% with the addition of the Fiat 500, Ford Fiesta and new VW Jetta models. The United States follows Mexico with an 8% increase, while volume in Canada is off 1%— hurt by production losses from Honda and Toyota. 

October 2011 | QUALITY

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NEWS Vehicle inventory has decreased to a 49 days’ supply at the beginning of August, down from a 54-day level in early July, mainly due to the typical July shutdown at many of the assembly plants. Car inventory was at 40 days, while truck supply was at 58 days— both low for their respective norms. Several manufacturers continue to have limited availability: Hyundai/Kia with a 19-days supply and Honda with a 28-days supply. Production continues to support inventory replenishment, but closer-to-normal industry levels are expected to be reached by October.  The 2011 North American production outlook has been trimmed slightly, but it continues to round to 12.9 million units. The decrease is the result of the reduction in the outlook for vehicle sales, but it is not as severe due to the current low level of inventory. Had the sales pace returned to the strength shown at the beginning of 2011, production would have needed to be increased in order to meet the demand and replenish inventory levels by the end of the year. 

BOEING 787 DREAMLINER RECEIVES FAA, EASA CERTIFICATION EVERETT, WA—Boeing received certification for the all-new 787 Dreamliner from the U.S. Federal Aviation Administration (FAA) and the European Aviation Safety Agency (EASA) during a ceremony at the company’s Everett, WA, facility.  FAA Administrator Randy Babbitt presented the U.S. Type Certificate, which verifies that the 787 has been tested and found to be in compliance with all federal regulations, to 787 Chief

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BUSINESS NEWS GLOBAL TEST SUPPLY (Wilmington, NC) announced it received a ranking of No. 1715 on the fifth annual INC. 5,000 list of America’s fastest-growing companies. For the second consecutive year, the company has earned recognition on this list of the nation’s fastest-growing private companies. Global Test Supply’s strong growth trajectory continued upward with a 60% increase in sales over the preceding year, and a three-year sales growth of 156%. The B2B Web-and-mortar business has achieved success through its innovative business management technology, aggressive SEO strategies and emphasis on customer service. MECMESIN CORP. (Sterling, VA), a supplier of tensile, compression, material and torque testing machines for quality control and product testing, has launched a new Web site specifically for North American customers. The site, www.mecmesincorp.com, features a fresh new look and navigation, enabling customers to easily search Mecmesin’s extensive range of test equipment by test application, product category or industry. AGILENT TECHNOLOGIES (Santa Clara, CA) and LOCKHEED MARTIN (Bethesda, MD) officials in the United States are teaming to offer a new service: calibration of test and measurement equipment. Agilent and Lockheed Martin now provide on-site services covering a full range of test and measurement equipment, from torque wrenches to spectrum analyzers. Agilent and Lockheed Martin personnel can calibrate instruments from nearly all manufacturers, either while on site or returning the instruments in less than 24 hours. SGS (Geneva, Switzerland) announces the acquisition of ACUMAX LTD. headquartered in Gauteng, South Africa. Acumax specializes in nondestructive testing, rope access services and ultrasonic inspections. Acumax serves the industrial, oil and gas and offshore industry in South Africa and the coast of Africa. HEXAGON METROLOGY (Wadgassen, Germany) delivered its 100th DEA Global 7.10.7 coordinate measuring machine, made in Turin, Italy, to HIRSCHVOGEL UMFORMTECHNIK GMBH (Denklingen, Germany). The Hirschvogel Automotive Group is a manufacturer of forged steel and aluminum parts. More than 3,000 employees worldwide produce components for the automotive industry and its system suppliers. SPECTRIS PLC (Egham, England), the instrumentation and controls company, has signed an agreement to acquire the Omega Engineering business. Omega is a supplier of process measurement and control instrumentation for automation, wireless, test and measurement, process control, power monitoring, environmental and lab equipment.

Pilot Mike Carriker and 787 Vice President and Chief Project Engineer Mike Sinnett, both of whom have worked on the program since the day it began.  Babbitt presented the amended Production Certificate 700 to John Cornish, vice president of 787 final assembly and delivery, and Barb O’Dell, vice president of quality for the 787

program. The production certificate adds the 787 to the list of Boeing Commercial Airplane production systems that have been found to be compliant with all federal regulations.  “Certification is a milestone that validates what we have promised the world since we started talking about this airplane,” says Boeing Commer-

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cial Airplanes President and CEO Jim Albaugh. “This airplane embodies the hopes and dreams of everyone fortunate enough to work on it. Their dreams are now coming true.”  Patrick Goudou, executive director of EASA, presented Dan Mooney, vice president of 787-8 development, and Terry Beezhold, former leader of the 787 Airplane Level Integration Team, with the European Type Certificate for the 787.  Scott Fancher, vice president and general manager of the 787 program for Boeing, wrapped up the event addressing the broad team of those who worked on the program.  “This is truly a great airplane,” Fancher says. “From the advanced materials and innovative technologies to the improved passenger experience and unbeatable economics, the 787 really is a game-changing airplane.”

FIRST LABORATORY FOR LARGE GEAR MEASUREMENT OPENS IN GERMANY BREMEN, GERMANY—The Bremen Institute for Metrology, Automation

and Quality Science (BIMAQ) at the University of Bremen opened the Laboratory for Large Gear Measurement on August 5, 2011. The facility is Germany’s first university laboratory for the inspection of large gear wheels. The Bremen researchers can now measure toothed gear components from wind turbines. They also can investigate the interrelationships between design, manufacture, quality and functional characteristics of large gears and their effects on aspects such as wear, service life, types of defect and noise. The aim is to extend the life of large gearboxes in wind turbines. 

PWC: GLOBAL INDUSTRIAL MANUFACTURING M&A VALUE INCREASES 70% IN SECOND QUARTER OF 2011 NEW YORK, NY–Merger and acquisition (M&A) value increased 70% in the industrial manufacturing sector during the second quarter of 2011, according to Assembling Value, a quarterly analysis of M&A activity in the global

industrial manufacturing industry by PwC US. In the second quarter of 2011, there were 46 deals that were worth more than $50 million with a total deal value of $18.6 billion, compared to 33 deals and $9.8 billion in the second quarter of 2010. Average deal value was relatively flat at $400 million in the second quarter of 2011 compared to the prior quarter and up from $300 million in the same period of 2010.  In the first six months of 2011, both deal volume and value were up with 86 deals—worth more than $50 million— and a total value of $35.9 billion, an 83% increase in volume and 197% increase in value when compared to the 47 deals worth $12.1 billion in the first six months of 2010.  “The maturity of the industry, a fairly high market concentration and favorable deal valuations were factors that drove and will continue to drive deal activity in the industrial manufacturing industry,” says Barry Misthal, global industrial manufacturing leader for PwC. “In the near-term, continuous global economic growth, fueled by emerging markets,

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NEWS greater capital availability and more cash on balance sheets should continue to aid strong deal activity in the industrial manufacturing sector.  “In fact, a recent survey we conducted with executives at large, multinational U.S. industrial manufacturing companies found that while a number of global factors contributed to the uncertainty about the world economy of late, U.S.-based industrial manufacturers continued to grow international sales last quarter and remain bullish on overseas revenues,” says Misthal. “In spite of the recent market volatility, PwC believes that the outlook for deals in the space is encouraging.”  In the second quarter of 2011, U.S.affiliated transactions dominated M&A activity for deals worth more than $50 million, making up 41% of total deal volume and 66% of total deal value, with 19 deals with a total deal value of $12.3 billion.  Strategic investors continued to drive deal activity in the second quarter of 2011 with approximately 80% involved in deals worth more than $50

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Edmund Optics (Barrington, NJ), leading supplier of optical components, is proud to announce the recent election of Robert Edmund, CEO and chairman of the board of Edmund Optics, to the INTERNATIONAL SOCIETY OF OPTICS AND PHOTONICS (SPIE) senior member. SPIE senior members are members of distinction who are honored for their professional experience; their active involvement with the optics community and SPIE; and their significant performance that sets them apart from their peers. Two hundred twelve SPIE members have received this promotion since the senior member distinction.

million, compared to nearly 20% from financial investors. In the first half of 2011, nearly 78% of strategic investors were involved in deals worth more than $50 million, already exceeding the involvement of strategic investors for all of 2010 with approximately 76%.  “The mature and saturated nature of the industry is driving companies to seek growth opportunities through further consolidations within the industrial manufacturing sector,” Misthal says. “Even though financial and credit conditions have improved, financial investors have not yet made a strong return to this sector, and the slowdown that began during the second quarter of the year has negatively impacted financial investors’ interest.” 

According to PwC, mega deal activity, or transactions worth $1 billion or more, was entirely driven by strategic investors in the second quarter of 2011, confirming the strong desire of these companies to realize growth through acquisitions. During the second quarter of 2011, there were three mega deals with a total value of $7.7 billion, compared to three mega deals worth $4.4 billion in the second quarter of 2010.  “Small and undisclosed value deals continued to dominate deal activity in the second quarter of 2011 as strategic and financial investors are approaching prospective transactions with increased caution. Although globalization remains relevant, companies are shifting their focus toward deals that can





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America Inc. (NNA) granted $85,000 to the American Indian College Fund to continue the Nissan Corporate Scholars Program. The program has provided scholarships to Native scholars attending tribal colleges and mainstream universities for more than a decade. The renewed grant will support 10 tribal scholarships of $3,000 each per year and five mainstream scholarships of $5,000 each per year. Students

must be enrolled in college full-time, have a 2.5 cumulative grade point average, and demonstrate leadership and commitment to the Native community to be eligible. Preference is given to renewing Nissan scholars. Nissan also is a $20,000 sponsor of the Fund’s annual Flame of Hope Fundraising Gala on October 20, 2011. The event raises both awareness and funds to help students in Indian Country

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provide new strategic opportunities and synergistic growth,” Misthal continues. “Going forward, mega deal activity is expected to continue to be restrained by companies and financial investors’ conservatism in pursuing large transactions along with the growing uncertainty of the industrial manufacturing sector. However, despite the improving macro-economic conditions, companies are likely to continue to deleverage and invest in smaller, bolt-on acquisitions.”  For deals worth $50 million or more, the industrial machinery category was the primary driver of deal activity with 61% and one of the three mega deals in the second quarter of 2011. The number of fabricated metal products deals increased to 20% during the second quarter of 2011 from 12% in the same period of 2010.  The pace of global domestic market transactions has already exceeded all of 2010, which represented approximately 58% of deals worth more than $50 million, compared to nearly 72% during the second quarter of 2011 and nearly 61% in the first half of 2011. According to PwC, companies are pursuing more local consolidations as growth tools, as both the emerging and some developed markets have already taken steps to restrain unsustainable growth in order to control inflationary pressures.  “As firms within the emerging markets grow and become financially stronger, they are likely to pursue opportunities within their local economies, since there is less risk in local transactions. Their economies’ growth is expected to surpass the growth in the developed world,” Misthal adds.  Global domestic deals across all regions led deal activity with North America contributing 13 deals and both Asia and Oceania and Europe contributing 10 deals. Interestingly, Asia and Oceania’s stake in total transactions decreased both in terms of volume and value during the second quarter of 2011 with 30%—or 14 deals worth more than $50 million, compared to 41%—or 11 out of 27 deals during the second quarter of 2010. 

DENVER—In support of American Indian higher education, Nissan North

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NEWS achieve their educational and career goals. “The Nissan Foundation aims to build community through valuing cultural diversity,” says Scott Becker, chairman of the Nissan Foundation. “By encouraging Native American students to continue their education, our hope is that they, in turn, will strengthen and bring greater value to their communities.”

Rochester campus, says University President Joel Seligman. Slaughter secured a total of $4.4 million in federal money across three funding cycles to make the project possible. The work started in 2007, recalled Slaughter, who championed the lab for its job- and company-creation potential. It will “train the next generation of scientists and engineers in nanotechnology,” she adds.

NANO RESEARCH CENTER OPENS AT UNIVERSITY OF ROCHESTER

IN MEMORIAM

ROCHESTER, NY—The University of Rochester, joined by U.S. Representative Louise Slaughter, opened the Integrated Nanosystems Center (URnano) on campus. The center will be used for nanoscale physics, optics, chemistry, biomedicine and bioengineering research on commercialization of fuel cells, biosensors and other high-tech devices. URnano comprises a 1,000-square-foot metrology facility and a 2,000-square-foot cleanroom for fabrication. Slaughter helped bring the “impressive, state-of-the-art facility” to the

Frank Koch, president and founder of DeFelsko Corp. died peacefully in hospital on August 8, 2011, at the age of 77 with his loved ones by his side. Born and raised in Germany, Koch was formally trained as a tool and die maker before emigrating in 1956. In the 1960s, Frank’s entrepreneurial spirit led him to Ogdensburg, NY, where he started several successful businesses including DeFelsko Corp. It was his involvement with coating thickness and test instruments that most defined his career. Koch began importing and selling inspec-

tion instruments from Germany in the early 1960s and soon moved into manufacturing beginning with the PosiTest mechanical pulloff gage and continuing with the ever-expanding PosiTector series of inspection instruments. His ability to understand the needs of the inspection community and to make instruments that were rugged and easy to use set Koch apart from his peers. Under his leadership, DeFelsko pioneered many technologies including hand-held ultrasonic coating thickness gages, auto switching ferrous/nonferrous coating thickness gages and unique self-aligning adhesion testers. Through his vision and the team he inspired, his company evolved from a one-man operation to a world leader in the design and production of quality, handheld test equipment. Today, the company he started employs more than 50 people at their facility in Ogdensburg, NY, and houses research, manufacturing, sales, shipping and service departments.

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FACE OF QUALITY

CONTINUOUS IMPROVEMENT IS

A TEAM EFFORT

CONTINUOUS IMPROVEMENT IS ABOUT COMMITMENT, RIGOR AND DISCIPLINE.

I

JIM

n previous columns I’ve written about the importance of continuous improvement. We’ve focused on the human side of quality and the power of incremental improvement. Now let’s take the discussion into a different aspect of continuous improvement. Another characteristic of the meaning that I give to improvement is that improvement also is dependent L. SMITH on factors other than human influence. Certainly, in my opinion, which is supported by 45 years of work experience, the criticality of the human side of quality cannot be denied. However, getting people to work smarter, or harder for that matter, in poorly designed or poorly functioning processes will produce minimal improvement at best. Remember what W. Edwards Deming said about design and workplace processes as well as the supporting processes? “The system is responsible for 94% of the probTo be of lasting substance, lems” and who owns the system? improvement must be a Management must continuous process. assume the responsibility of creating an environment which continuously improves the system. One of the ways in which management can create this environment is to work to institutionalize continuous improvement to make it a way of organizational life. When organizational improvement performance shows significant gain, the improvement is not just the sum of individual performances. It also is the result of improved processes and the synergistic result of team performance. Assembling individuals into teams transcends the capacities and limits of individuals, and integrating teams into a larger whole, thus transcending the capacities and limits of the organization. Significant improvements in the quality of products, services and increased customer satisfaction result from improvements in work processes. These work processes are not under the control of any one person. They are under the control of a variety of people who function in one type of organizational team or another, for example, work teams and project teams. Individuals certainly have an influence on their sphere of work being performed, and that influence has an impact, positively or negatively, on the result. However, when individuals are formed into synergistic

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QUALITY | October 2011

teams, they can have tremendous influence to improve customer satisfaction and work processes through teamwork augmented by the assistance and cooperation of their fellow associates. On an individual basis, we will not be totally successful in obtaining the level of performance excellence that is needed for an organization to survive and prosper. We can’t obtain significant improvement by strengthening the motivation of individuals or by getting people to work harder. Many studies indicate the vast majority of people are already committed to doing their best. What’s needed is for management to focus on improving skills and knowledge of their people to help them work together in a more synergistic way to improve the robustness of their processes. There is one more distinctive characteristic in the meaning that I give to improvement and that’s measurement. To be of lasting substance, improvement must be a continuous process. Until improvement is institutionalized, it will never be viewed as a regular and routine part of performance. Until it is viewed as the norm, improvement will continue to be a response to organizational pain that cascades through an organization. Responding to pain—for example, taking care of customer issues—is absolutely essential. However, if organizations remain stuck at this level, they will not institutionalize continuous improvement. Organizations shouldn’t be focused on any particular method or tool as continuous improvement is more about commitment, rigor and discipline than it is about technique. Making continuous improvement part of the organizational fabric is paramount if we want to experience everyone pulling together and working toward the same end. 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].

Visit www.qualitymag.com to read Jim Smith's weekly blog, Jim's Gems.

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OTHER DIMENSIONS

CALIBRATION:

YOU GET WHAT YOU PAY FOR BUYER BEWARE: NOT ALL CALIBRATION REPORTS ARE THE SAME.

T

he title for this column would seem self-evident— pay less, get less. However, too many people believe someone offering calibration for well under market price can provide the same level of competence and detail as their more expensive competitors. Many buyers consider calibration reports to be the same with price or delivery the only differences HILL COX between them. This is not the case when you consider how lower prices come to be. Here are some of the shortcuts that are taken when prices become more important than competence. • The lab in question is not accredited to ISO 17025 by a reputable agency. This saves the lab money, but when it comes to competence, you’ll have to take its word for how good it thinks it is. Can you afford to save, • No data, just opinions; for example, pass or say $10, on the calibration of fail. Until recently, a a gage that will be used to calibration report did not have to show data verify $20,000 or more in as long as it was available on request. This component parts? meant that a lot of reports were next to useless. Without the data, customers had no way of knowing the actual state of their gages or how many features were actually calibrated. By the end of December of this year, all A2LAaccredited labs will have to show data on their reports or the reports will not be accredited. Most other accrediting agencies are changing their rules as well. • Sometimes labs put so little data on a report that it means little. An example is reporting a reading from the front and rear of the go gage member, eliminating one in the center to reduce costs. If the reading at the front was undersize and the one at the rear is just inside the top limit, one could assume the gage is badly tapered. If there was a reading in the center and it was the same as the rear reading, a different picture emerges. On thread gages, some labs only report one or two PD readings, and ignore the major diameter. The low cost is obtained through a low level of information. • One way to offer cheaper calibration on new gages is to offer a certificate instead, one that may use data from the shop floor. You’re basically paying for a typing service.

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• Certificates of compliance or conformance are often substituted for proper calibration reports and auditors often accept them. These are the ultimate cheap report since they aren’t a report at all. In fact, such documents were never intended for use with gages. They are so useless, most companies give them away. • A major cost for calibration laboratories is the equipment required for the work being done. Cost cutters can reduce this by using equipment that is not as good as it should be. If the lab is not accredited, and no statement of measurement uncertainty is provided, you’ll never know if the equipment and/ or masters being used are suitable. The only way to protect yourself is to visit the lab to see what equipment is actually being used, however, even this may not be enough. I know of one gage maker that had a “lab” with all sorts of fancy equipment in it but a warning on the door prevented visitors from going inside. You could watch from the windows, of course, and might actually see someone in there on occasion. Had you been able to go inside, you would see that the room was decorated with unworkable equipment that could not be used for anything except to impress visitors. The actual calibration was done elsewhere in the plant. A reputable gage maker bought out the company and is doing things the right way. But similar dog and pony shows pop up from time to time on a smaller scale. • Another cost component for those who calibrate a lot of gages are the standards they are made to. Cost cutters don’t bother buying these documents from the creators of them and use secondhand material or rely on computer programs which may not match the original data. Where threads are involved, up to 14% of the numbers generated by a computer program will differ from the published values that are the only correct ones. Pay less, get less. Can you afford to save, say $10, on the calibration of a gage that will be used to verify $20,000 or more in component parts? It’s a gamble to be sure. Do you feel lucky? Hill Cox president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

October 2011 | QUALITY

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QUALITY 101  Dual purpose magnetic induction and eddy current gauges and probes would be beneficial in the case of an automobile where the doors might be steel and the hood might be aluminum. Source: Fischer Technology

results and help guarantee the integrity of the data.

UNDERSTAND

COATING THICKNESS MEASUREMENT TEST METHODS

Develop a working knowledge of the test methods related to coating thickness measurement and the instruments available for both common and complex applications. BY PAUL LOMAX

I

mproving quality while reducing costs is a never-ending goal shared by small one-person companies, as well as by large organizations. Since virtually everything that we are surrounded by has a coating, it stands to reason that tightening tolerances by using coating thickness measurement technology will help the bottom line. This is true for in-house plating and painting applications, companies that perform incoming inspection of goods from suppliers, and third-party inspection firms and consultants. A reduction in costs also can take place by streamlining the time and effort it takes to evaluate the measurements and make adjustments to the process. Less administrative time equates to more time fine tuning.

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QUALITY | October 2011

In order to improve quality and reduce costs, it is important to have a working knowledge of the test methods related to coating thickness measurement and the instruments available for both common and complex applications. Most importantly, the operator should note that just because a test method is capable of measuring a coating, it might not necessarily be the best test method available. We will discuss available test methods and point out some of the key factors an operator should consider before selecting the proper instrument. Recognizable applications, such as household fixtures, automobile parts and fasteners will be used as examples. We also will discuss a means to streamline the measurement

TEST METHODS Common and complex plating and other coating thickness applications are typically measured using one of the following test methods: X-ray fluorescence, coulometric, beta backscatter, magnetic induction, amplitude eddy current and phase-sensitive eddy current. Energy dispersive X-ray fluorescence analysis (ED-XRFA) is a method for measuring the thickness of coatings and for analyzing materials. It can be used for the qualitative and quantitative determination of the elemental composition of a material sample, as well as for measuring coatings and coating systems. It works nondestructively and without contact. Measurements can be completed quickly and usually without extensive sample preparation. With ED-XRFA, it is possible to measure both thickness and chemical composition of homogeneous materials and coatings. Even traces of harmful substances can be detected in the widest variety of samples. Moreover, X-ray fluorescence analysis is a very clean method because no chemicals are used. CHROME/NICKEL/COPPER COATINGS OVER PLASTIC One of literally thousands of examples where X-ray fluorescence would be the test method of choice is the task of measuring chrome, nickel and copper coatings applied to a shower head. In most cases the substrate is plastic, thus eliminating most other test methods from being able to perform the measurement. Furthermore, X-ray fluorescence is capable of measuring each individual layer of the decorative chrome in the range of 0-5 microns or less, the nickel coating of 5-10 microns, and the copper layer which might be 30 microns or greater.

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QUALITY 101

Multiple test methods could be used for the same task. One such example is the measurement of zinc plating over steel. Source: Fischer Technology

As previously mentioned, X-ray fluorescence is nondestructive, providing a major advantage. Care should be taken with regard to the alignment of the part to the detector and correctly focusing the video on the measuring point. The estimated or target thickness of the copper also should be considered in determining if X-ray fluorescence is the most appropriate test method. All things considered, X-ray fluorescence is ideally suited for this application, but it is not the only test method capable of measuring the chrome/nickel/copper coatings over plastic. The coulometric method measures nearly all metallic coatings including multiple coatings on any substrate material, such as plastic. It is, however, a destructive method because the coatings are successively removed at the measuring area and determined by the time taken for removal. X-ray fluorescence might still be the preferred choice because it is quick and nondestructive. However, the operator should consider the size of the part and if it will fit inside the chamber of the X-ray system—X-ray chambers can be modified for large parts—and if there might be other alignment or focusing issues that might occur. The thickness of the copper might also determine which method is best. If, for instance, the copper thickness is up to 50 microns, then the coulometric method could be an important complement to the XRF method. The beta backscatter method allows for the thickness measurement of

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QUALITY | October 2011

Many times hard copy documentation of inspection reports is required. Importing, copying and pasting measurement results into inspection forms are an administrative burden and can lead to mistakes. The direct population of measurement results from the gage to virtually any report template will help reduce the likelihood of errors. Source: Fischer Technology

organic and metallic coatings on various substrate materials. Even soft coatings, such as well as oil and lubricating films, can be determined with the appropriate probe configuration. Those that have thickness measurement applications that include organic and metallic coatings might choose beta backscatter over other methods because of the wide assortment of coating/ substrate combinations that this method is capable of measuring. In addition, beta backscatter is nondestructive. Magnetic induction and eddy current test methods represent some of the most recognizable coating thickness instruments available. Magnetic induction instruments measure the thickness of nonferromagnetic metal coatings such as chrome, copper, zinc, paint and powder coating over steel and iron. The amplitude eddy current method measures paint, powder coating, as well as anodize coatings over aluminum, stainless steel, copper and brass. Depending on the capabilities of the particular instrument, there are dual-purpose magnetic induction and eddy current gages and probes. An example when these capabilities would be beneficial is in the case of an automobile where the doors might be steel and the hood might be aluminum. The ability for the device to automatically detect the substrate material and apply the appropriate test method is crucial. It reduces time, reduces the likelihood of erroneous measurements being taken and thus reduces time and costs.

STANDARDS ASTM D7091 Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nonconductive Coatings Applied to Non-Ferrous Metals is a resource for those working with many of the aforementioned applications. Additional test methods have their own ASTM and ISO standards. It is necessary for users to understand that not all gages and probes are ideally suited for all applications. Operators should review specifications such as trueness which is determined using calibration standards of known thicknesses. Trueness can be stated as an absolute value or as a percentage. Another criterion of a particular system is the precision or repeatability standard deviation of X number of single readings. Other factors include the performance of the gage or probe when measuring concave or convex diameters, the minimum measurement area required, the performance of the gage or probe in relation to the distance of the probe tip to the edge of the part being measured, and the performance of the gage and probe as it relates to the substrate thickness. Additional criteria to be considered in the selection process is the shape of the part that needs be measured, the type or types of substrates the coating is being applied to, and whether the user requires just a spot checker or an

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instrument that provides memory and download capabilities.

resulting in unintentionally skewing of the statistical results of the data. The direct population of measurement results from the gage to virtually any report template will help reduce the likelihood of errors. There are multiple test methods available for coating thickness mea-

New

Paul Lomax works at Fischer Technology (Windsor, CT). For more in formation, call (860) 298-6069, e-mail plomax@fischer-technology. com or visit www.fischer-technology.com.

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INSPECTION PLANS AND REPORT TEMPLATES Streamlining the measurement and documentation process is often cumbersome. Making sure the correct number of readings is taken and in the right sequence is extremely important. If done correctly, a selective analysis of different parts or areas on each part can be evaluated. For example, the spray patters on each automobile door, hood and trunk could be looked at individually. Adjustments can then be made to the spray patterns. Quick meaningful evaluations and adjustments to a process have a direct effect on the bottom line. Many times hard copy documentation of inspection reports is required. Importing, copying and pasting measurement results into inspection forms are an administrative burden and can lead to mistakes. A 5.30 mil value could mistakenly be typed as 3.50 mil,

Common and complex plating and other coating thickness applications are typically measured using one of the following test methods: X-ray fluorescence, coulometric, beta backscatter, magnetic induction, amplitude eddy current and phase-sensitive eddy current. Source: Fischer Technology

  

ZINC PLATING OVER STEEL Another example where multiple test methods could be used for the same task is the measurement of zinc plating over steel. Magnetic induction will measure zinc over steel; however, the spot size and measurement area might be too small for truly meaningful results. Likewise, X-ray fluorescence will measure these parts but cost and the portability of a handheld instrument could be a factor in the decision. In this case, the phase-sensitive eddy current measurement test method should be utilized (ISO 21968). The phase sensitive eddy current method allows for the measurement of metallic coatings on any substrate. This method also is advantageous for this example because it is capable of measuring small objects, such as nuts, bolts and screws. In other words, the shape of the part has very little influence on the results of the reading. Likewise, measurements of zinc or copper on steel over rough surfaces can be measured. Therefore, truer and more repeatable results can be expected with this technique than with other traditional test methods for this example.

surement requirements. Utilizing the appropriate test method for the specific application is necessary. Therefore, performance capabilities such as the trueness of the gage and probe should be considered, particularly in regards to factors that influence the readings. In addition to the capabilities of the gages and test methods, the operator is encouraged to take advantage of technological developments that have greatly enhanced efficiency through hardware and software capabilities. These developments reduce the likelihood of errors. It also provides a selective analysis of parts or areas on each part to be evaluated. Quicker and more meaningful data through paperless inspection and report templates allow for adjustments to the process. These adjustments will result in the improvement of quality and reduction of costs.

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October 2011 | QUALITY QLT10114STAR.indd 1

25 9/14/11 9:14 AM

INNOVATIONS  Verisurf Validate software’s automated comparison processing returns a simple and obvious pass-or-fail result. Source: Verisurf

NOT LOST IN

TRANSLATION The growth of computers and computer-aided tasks has produced many different formats and languages, all of which can complicate the ability to communicate. BY DARRYL SELAND, EDITOR IN CHIEF

T

against translation errors. Verisurf Valhere are literally hundreds of ways to idate provides precise computer-aided communicate. Human beings speak design (CAD) model translation validamany different languages with a host tion by comparing the authority CAD of dialects, cultural slang and euphemodel to the translated CAD model, misms, not to mention the numerous enabling manufacturers to quickly non-verbal ways we communicate with identify any translation errors. one another. The same can be said of “There are numerous examples of our technology. The growth of computcostly manufacturing problems and ers and computer-aided tasks has proeven product failures due to use of duced many different formats and lan‘bad CAD’ for engineering simulation, guages, all of which can complicate the manufacturing and inspection,” ability to communicate. says David Olson, direcNo one is more aware of SPECIFICATIONS tor of sales and marketthe potential disconnects » Native support for all major ing at Verisurf. “As supand errors in translation CAD model formats ply chains become more than manufacturers and » Directly supports CQI global the chances for OEMs using emerging 3-D initiatives bad parts from bad CAD model-based definition » Complies with OEM quality increases. Many Verisurf (MBD) environments. requirements for data integcustomers are manufacVerisurf Software Inc.’s rity management turers with high industry (Anaheim, CA) Validate compliance requireis a tool that bridges these » Validates CAD model transments such as aerospace, disconnects and guard lations and legacy CAD data

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QUALITY | October 2011

defense and medical, which now require proof of translation validation with submittal of AS 9102 first-article inspection documentation.”  Model based definition (MBD), also known as digital product definition (DPD), uses 3-D digital data within the CAD software to provide specifications on components and assemblies, including the models and their metadata, geometric dimensioning and tolerancing (GD&T), component level materials, assembly level bills of materials, engineering configurations and design intent. This annotation replaces older methods that required the inclusion of 2-D drawings to provide such information. These older methods took advantage of the idea that the human mind can understand 3-D data more readily than 2-D data. The drawback was the need to reuse and organize the information and recreate that information in an additional file, resulting in more files to be managed, additional time to recreate product information and more chances for error. MBD cleared the hurdle of making the process more efficient and less time consuming, but the chance for translation error still exists. Manufacturing suppliers rely on OEMprovided 3-D CAD models as the data source for downstream operations such as numerical control (NC) programming, machining and inspection. OEMs now require suppliers to provide quality assurance process documentation that proves the accuracy of all translated CAD models back to the authority CAD model. Add in global competition, modern continuous quality improvement (CQI) best practices, the high cost of rework and the threat of litigation, and one can see how there is a demand for eliminating potentially costly CAD-file translation errors as early as possible in the manufacturing process. Verisurf’s Validate software provides the ability to specify validation tolerances that control the acceptance of a 3-D shape’s dimensional integrity. The automated comparison processing returns a simple and obvious passor-fail result. The system generates a comprehensive validation report with

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an encrypted validation certificate. A digital fingerprint embedded in the report ensures authenticity. Verisurf Validate handles models from all major CAD/CAM (computer-aided manufacturing) systems natively without the expense of any additional CAD licenses. The software validates the migration of legacy CAD data and also complies with OEM quality requirements for data integrity management and satisfies the Boeing D6-51991—Quality assurance standard for digital product definition. “A common example is Boeing’s D6-51991 requirements, Quality Assurance Standard for Digital Product Definition,” says Olson. “[Which] specifically states, ‘Acceptance criteria for accuracy of translated surface profile/ geometry [tolerance] must be determined by the supplier, and must ensure the end product will be within engineering tolerance/specification. Objective evidence of translation validation must be retained. [Typical allowable deviation tolerance is 0.0001 to 0.001 inch].” Depending on the version, Verisurf’s software will validate:

IGES STEP Parasolid ACIS Dassault Systèmes SolidWorks Autodesk Inventor Kubotek KeyCreator STL Dassault Systèmes CATIA V4 and V5 • Siemens NX • PTC Pro/Engineer • • • • • • • • •

Olson adds, “Verisurf Validate is the only inspection and measurement software with translation validation so it was very well received at CMSC [Coordinate Metrology Systems Conference] 2011 where there were many aerospace manufacturing, quality assurance, inspection and metrology engineers that must prove compliance to validation requirements.”

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October 2011 | QUALITY

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50 YEARS OF QUALITY

Universal Testers Through the Years

There are many types of testing machines. The most common are universal testing machines, which test materials in tension, compression or bending. This month 50 Years of Quality takes another look at universal testers. EXTEND THE LIFE OF MATERIALS TESTING EQUIPMENT, MAY 2003 Is the performance of your material test equipment limited by aging components and outdated controls? If you have an aging mechanical dial, digital display or chart recorder, or an outdated computer control system, now might be the perfect time to upgrade your testing equipment. An upgrade allows you to retain your existing load frame, grips and load cells, while replacing older electronics and recording devices with a new controller and advanced testing software. The result can be a revitalized system at a fraction of the cost of new testing equipment. Upgrading equipment enables the integration of your testing procedures with your business operation. Automated test control increases the

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QUALITY | October 2011

repeatability of test results, while PC storage, automated calculation and networking capabilities enable statistical analysis and data archiving, leading to improved productivity and more reliable results. IDENTIFY UPGRADE CANDIDATES Before purchasing an upgrade, evaluate your system by performing a visual inspection of the frame, operating the machine, and gathering data about its capacity and transducers. If the frame of your testing system can’t be calibrated, exhibits signs of backlash or has broken parts, retrofitting the system’s electronics will not improve its performance. The first step in any evaluation is to determine if the system is mechanically or hydraulically powered. Mechanical testers use an electromechanical drive

system to supply torque power to the load frame. A standard system consists of a servocontrolled drive motor, timing belts and two screw columns. Hydraulic systems use a hydraulic fluid and a pumping unit—often called a hydraulic power pack—to supply the forces necessary for tension, compression or cyclic testing. On mechanical systems, all gears, pulleys, belts, chains and critical frame parts should be visually inspected before retrofitting the system. Start by walking around the testing frame and viewing the columns from all angles. Columns are often bent from off-center loading or incorrect lifting. If the columns are bent, machine alignment is jeopardized and uneven loading will occur. Next, remove the cover that encloses the mechanical assembly and electronics. Look for worn gears, broken teeth, frayed belts and loose chains. If parts are severely damaged, consider the cost and availability of replacement parts. For hydraulic equipment, screw columns, crosshead pockets and critical

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frame parts should be visually inspected before an upgrade is purchased. As with mechanical testers, start by walking around the testing frame to check for bent columns. Static universal testing machines may include stay plates to hold the columns in place. Check to ensure that these plates are not bent. Replacing bent stay plates may require complete disassembly of the frame. If the testing frame includes inhead gripping pockets, they should be inspected for wear. Incorrect use of grips and filler plates can result in crosshead deformation. Severe deformation will affect the gripping and loading of specimens. A repair requires the crossheads to be removed from the frame so the pockets can be remachined. Finally, look for hydraulic fluid leaking from the piston assembly. Machines that are leaking oil may not be able to reach capacity. This fix could be as simple as replacing the seal, or it could require a new piston and cylinder assembly. TENSILE TESTING BASICS, TIPS AND TRENDS, JANUARY 2005 There are many types of T Tensile Testing Basics, ttesting machines. The Tips and Trends most common are unim vversal testing machines, which test materials w S iin tension, compresssion or bending. The primary use of the p testing machine is to t create diagram. Once t the th stress-strain t the diagram is generated, a pencil and straight edge or computer algorithm can be used to calculate yield strength, Young’s Modulus, tensile strength or total elongation. There are two classes of testing machines, electromechanical and hydraulic. The electromechanical machine uses an electric motor, gear reduction system and one, two or four screws to move the crosshead up or down. A range of crosshead speeds can be achieved by changing the speed of the motor. A microprocessor based closed-loop servo system can be implemented to accurately control the speed of the crosshead. A hydraulic testing machine uses either a single- or dual-acting piston to move the crosshead up or down.

QUALITY TEST & INSPECTION

Mechanical properties are an important measure of product quality, and tensile testing is just one way to certify the product. BY RICHARD GEDNEY

There are two classes of testing machines—electromechanical and hydraulic. Photo: ADMET Inc.

| TECH TIPS | ◆ There are two classes of testing machines, electromechanical and hydraulic. ◆ ASTM requires that load and strain measuring devices be calibrated annually or more frequently. ◆ Measuring small strains typical of a high-strength metals test—0.0001 inch or less—is the task of an extensometer.

46 QUALITY | January 2005

uccess in today’s marketplace requires improvements in efficiency, quality and accuracy of testing facilities and testing equipment. Testing machines are used to develop better information on known materials or to develop new materials and maintain the quality of the materials. For materials suppliers, the mechanical properties tested by these machines are an important measure of product quality, and testing is required for certification. In a broad sense, strength refers to the ability of a structure to resist loads without failure. Failure may occur by rupture because of excessive stress or may take place owing to excessive deformation. Tensile properties include the resistance of materials to pulling or stretching forces. The amount of force required to break a material and the amount it extends before breaking are important properties. For most materials, the initial resistance to force, or modulus, and the point of permanent deformation, are obtained from plots of force against elongation. Analysis of forceelongation or stress-strain curves can convey much about the material being tested, and it can help in predicting its behavior.

Machine design There are many types of testing machines. The most common are universal testing machines, which test materials in tension, compression or bending. The primary use of the testing machine is to create the stress-strain diagram. Once the diagram is generated, a pencil and straight edge or computer algorithm can be used to calculate yield strength, Young’s Modulus, tensile strength or total elongation. There are two classes of testing machines, electromechanical and hydr aulic. The electromechanical machine uses an electric motor, gear reduction system and one, two or four screws to move the crosshead up or down. A range of crosshead speeds can be achieved by changing the speed of the motor. A microprocessor based closed-loop servo system can be implemented to accurately control the speed of the crosshead. A hydraulic testing machine uses either a single- or dual-acting piston to move the crosshead up or down. In a manually operated machine, the operator adjusts a needle valve to control the rate of loading. In a closed-loop www.qualitymag.com

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In a manually operated machine, the operator adjusts a needle valve to control the rate of loading. In a closed-loop hydraulic servo system, the needle valve is replaced by an electrically operated servo-valve for precise control. In general, the electromechanical machine is capable of a wide range of test speeds and long crosshead displacements, whereas the hydraulic machine is a cost-effective solution for generating high forces. TENSILE TESTING BASICS, DECEMBER 2006 A tensile test is a static measurement of the effects of tensile force on a material or component, or to determine the bond strength of two materials that have been assembled together. By applying a tensile force on a material, one can find the tensile strength, yield point, yield strength, percent elongation, reduction in area and the modulus of elasticity. Tensile test results are used to indicate strength, ductility, stiffness and the correct parameters for heat treatment or processing. In general, tensile testers or universal testing machines apply the load mechanically by a screw and gears, or hydraulically with a pump and motor. A load cell device or pressure transducer is used to indicate the mechanical load applied to the test specimen. An extensometer is a device for measuring the extension or elongation of the test specimen. A computer that automatically runs the test machine—either by a selected strain rate, load rate or position rate—controls most new equipment. In addition, the computer can automatically calculate all of the properties needed by the operator. Tensile test specimens are normally shaped like dog bones—the center portion of the specimen is smaller in cross section than the two ends. Tensile specimens may be round or rectangular depending on the stock on which they are obtained. In most cases, the final results are reported in terms of pounds per square inch. Pounds per square inch is equal to the force divided by the cross sectional area. Most mechanical tests have been derived from testing metals. However, in materials testing, as the load is applied and the specimen is stretched,

a stress vs. strain curve is plotted. Many material properties can be Tensile found in this test such as Testing Basics yield strength, ultimate tensile strength, percent elongation and modulus of elasticity. For most materials, the initial portion of the test, the h relal tionship between the applied force, or load, and the strain or elongation of the specimen shows a linear relationship. Referred to as the proportional limit, Hooke’s Law or modulus line, it is where the material, if unloaded, would not show any permanent strain remaining when the stress is completely removed. Beyond this point is the yield point when strain occurs without an increase in stress. For metals and plastics the departure from the linear elastic region cannot be easily identified. Therefore, an offset method is used to determine the yield strength. Q UA L I T Y 1 0 1

and the specimen is stretched, a stress vs. strain curve is plotted. Many material properties can be found in this test such as yield strength, ultimate tensile strength, percent elongation and modulus of elasticity. For most materials, the initial portion of the test, the relationship between the applied force, or load, and the strain or elongation of the specimen shows a linear relationship. Referred to as the proportional limit, Hooke’s Law or modulus line, it is where the material, if unloaded, would not show any permanent strain remaining when the stress is completely removed. Beyond this point is the yield point when strain occurs without an increase in stress. For metals and plastics the departure from the linear elastic region cannot be easily identified. Therefore, an offset method is used to determine the yield strength. These methods are discussed in ASTM E8 (metals) and D638 (plastics). An offset is specified as a percent of stress that causes a specific amount of permanent strain—for metals, usually 0.2%. Starting at the origin of the curve, the offset is the horizontal distance between the modulus line and any line running parallel to it. Where this line intersects the stress strain curve is the offset yield point. Another important property is the ultimate tensile strength. This is the peak or maximum load the specimen sustains during the test. Percent elongation measures the ductility of the material. Most samples prior to testing are marked with a gage length, for example, 1 or 2 inches. The broken sample is put back together and the new gage length is then measured. The original gage is subtracted from the final, divided by the original and then multiplied by 100 to calculate percent elongation. Modulus of elasticity is the ratio of stress to strain in the initial portion of the curve below the proportional limit. The greater the stress required to product a given strain, the stiffer the material.

Tensile test results are used to indicate strength, ductility, stiffness and the proper parameters for heat treatment. Source: United Testing

What is Tensile Testing?

B Y J E F F M . RO U T L E Y

A

tensile test is a static measurement of the effects of tensile force on a material or component, or to determine the bond strength of two materials that have been assembled together. By applying a tensile force on a material, one can find the tensile strength, yield point, yield strength, percent elongation, reduction in area and the modulus of elasticity. Tensile test results are used to indicate strength, ductility, stiffness and the correct parameters for heat treatment or processing. In general, tensile testers or universal testing machines apply the load mechanically by a screw and gears, or hydraulically with a pump and motor. A load cell device or pressure transducer is used to indicate the mechanical load applied to the test specimen. An extensometer is a device for measuring the extension or elongation of the test specimen. A computer that automatically runs the test machine—either by a selected strain rate, load rate or position rate—controls most new equipment. In addition, the computer can automatically calculate all of the properties needed by the operator.

18

Tensile test specimens are normally shaped like dog bones—the center portion of the specimen is smaller in cross section than the two ends. Tensile specimens may be round or rectangular depending on the stock on which they are obtained. In most cases, the final results are reported in terms of pounds per square inch. Pounds per square inch is equal to the force divided by the cross sectional area. Most mechanical tests have been derived from testing metals. However, in materials testing, as the load is applied

GLOSSARY

 Tensile strength measures the force required to pull something such as rope, wire or a structural beam to the point where it breaks.

 Yield strength, or the yield point, is

the stress at which a material begins to plastically deform.

 Percent elongation measures the ductility of the material.

 Modulus of elasticity is the mathematical description of an object or substance’s tendency to be deformed when a force is applied to it.

Jeff M. Routley is the director of sales at United Testing (Huntington Beach, CA). For more information, call (800) 765 9997 x 242, e-mail [email protected] or visit www.unitedtesting.com.

QUALITY | December 2006

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MATERIALS TESTING MADE EASY, NOVEMBER 2007 Equipment has changed MATERIALS dramatically throughout the years, and the past Made Easy five years have been no exception. In Meredith Platt’s five years with Instron (Norwood, MA), she has seen a huge increase in the number of people looking at reproducibility and reliability studies. Platt, a 3300 product manager, says that it is important to measure how accurate the gage is, and then use that analysis to see whether the parts are good. The FDA monitors many of the companies Platt works with, so it is crucial to have everything running smoothly. Because of Instron’s application knowledge and product knowledge, they can provide input on the system and check its accuracy, Platt says. Generally most problems occur because of an operator issue or test configuration. A system’s success may depend on procedures, and how good the standard operating systems are. Software is important, as it is generally the operator’s main contact with the system. Software improvements over the past five years can improve test flow and prevent operators from missing steps along the way, Platt says. |

QUALIT Y T EST & INSPECT ION

|

TESTING Materials testing is a critical area of quality. Learn how it can improve the production process. BY MICHELLE BANGERT, SPECIAL PROJECTS EDITOR

N

o one wants a product to fail. A materials test can prevent problems from occurring. “Materials testing is commonly performed to assess the performance of materials such as metals, plastics and ceramics under stress,” explains Mark Fridman, marketing manager at Mark-10 (Copiague, NY). As such, it is a growing area, with changes ranging from equipment to standards to software. “Today’s software is more powerful, allowing for more configurable test procedures, protocols and data collection features,” says Fridman. “Lower cost and more basic materials testers also have recently been introduced by some manufacturers.” These lower cost, basic functionality materials testers have

been experiencing significant growth in recent years, including force measurement. “These newer machines share many of the same functions as their more sophisticated counterparts,” says Fridman, “However, their pricing, portability and ease of use allow them to be used for basic force measurement applications at the point of production as well as for more scientific analysis in quality and research laboratories.”

TESTING IMPROVES

The testing process itself also has undergone improvements. Formerly, operators might run a test, write down the results and then give their report to someone for data entry, with the information eventually residing in a corporate database. More and more companies are interested in streamlining the flow of data from the equipment into

An universal testing system can be used with a TouchPanel controller, rather than a computer and software, for simple QC tests in a lab or on the production floor. Source: Instron

TECH TIPS

Today’s materials testing software

allows for more configurable test procedures, protocols and data collection features.

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Regulations aimed to protect con-

Continued cost pressures on manu-

sumers will put more pressure on manufacturers to adhere to quality control standards.

facturers should make basic materials testers more prevalent and widely used.

QUALITY | November 2007

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October 2011 | QUALITY

10/21/07 9:07:52 PM

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50 YEARS OF QUALITY Usability, productivity, throughput and safety are all important to customers. “People are willing to spend extra money on systems that they know are safer,” Platt says. “The future benefit of equipment in general can’t put a price tag on safety.” However, price is still a consideration. “Most people are looking for a good value,” Platt says. “They want equipment they can trust, but they don’t want to pay a fortune for it.” Equipment is not the only thing that has changed—operator levels have dropped, says Platt. When Instron was founded, Ph.D.s were the ones using the equipment. Now, the Ph.D.s are not the ones operating the machinery. CHOOSE THE RIGHT EXTENSOMETER FOR EVERY MATERIALS TESTING APPLICATION, OCTOBER 2009 In materials and component testing the range of applications where extensometers are used is extremely diverse. As a result, the technical requirements for these devices are multifaceted, and there is no single device that satisfies all needs.

extensometer. The first meaThe requirements for an e sures small strains—typically extensometer are determined s up primarily by the characteristics u to 5 millimeters—very accurately in the elastic range, of the material to be tested. This a Extensometer and includes its shape and dimena the second measures very high extensions—typically sions, test requirements and h greater than 500 millimeters. the formal standards that must g Specimens with very be met. These define the gage smooth surfaces, or made of length, accuracy, test sequence s transparent materials, are not suitable and environmental conditions. for noncontact measurements without Having said this, the right choice first fixing measuring marks on the surof extensometer cannot be limited to face of the specimen. the basic material characteristics such One important consideration is the as specimen dimensions, stiffness, behavior when the specimen fails. Metals strength and plasticity alone. It also is and hard plastics will slip through the necessary to decide whether an extenknife edges of a contact extensometer someter can be connected directly to without damaging them, and rotatable the specimen without influencing the knife edges should be used to further load measurement or mechanically reduce the risk of damage even if the surdamaging the specimen itself. face of the specimen is particularly rough. Very thin specimens such as foils High extension or flexible specican be sensitive to clamping forces, mens can damage or destroy the knife while very small wire specimens do not edges and even the extensometer provide enough visible area for reliable itself due to whiplash, splintering or noncontact measurements. delamination of specimens. For these A high stiffness in the initial extenapplications noncontact measurement sion range, followed by high plasticity is a must. Q traditionally requires more than one |

QUALIT Y T EST & INSPECT ION

|

Choose the Right

for Every Materials Testing Application

I

n materials and component testing the range of applications where extensometers are used is extremely diverse. As a result, the technical requirements for these devices are multifaceted, and there is no single device that satisfies all needs. The requirements for an extensometer are determined primarily by the characteristics of the material to be tested. This includes its shape and dimensions, test requirements and the formal standards that must be met. These define the gage length, accuracy, test sequence and environmental conditions.

Materials testing success depends in large part on the characteristics to be tested. BY MANFR ED DR I PKE Having said this, the right choice of extensometer cannot be limited to the basic material characteristics such as specimen dimensions, stiffness, strength and plasticity alone. It also is necessary to decide whether an extensometer can be connected directly to the specimen without influencing the load measurement or mechanically damaging the specimen itself. Very thin specimens such as foils can be sensitive to clamping forces,

while very small wire specimens do not provide enough visible area for reliable noncontact measurements. A high stiffness in the initial extension range, followed by high plasticity traditionally requires more than one extensometer. The first measures small strains—typically up to 5 millimeters— very accurately in the elastic range, and the second measures very high extensions—typically greater than 500 millimeters.

TECH TIPS

 The right choice of extensometer cannot be limited to the basic material characteristics such as specimen dimensions, stiffness, strength and plasticity alone.

32

 It is necessary to decide whether an extensometer can be connected directly to the specimen without influencing the load measurement or mechanically damaging the specimen itself.

 The main advantage of noncontact video and laser scanning extensometers is that they can be used up to the breaking point without damage even when testing specimens exhibit whiplash.

QUALITY | October 2009

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MEASUREMENT

Air Gaging for

Orthopedic Devices Air gaging has become the inspection tool of choice for controlling critical parameters in the medical industry. BY GEORGE SCHUETZ

H

Tolerances become tighter and gaging igh precision orthopedic compoprocesses must increase their perfornents can only meet high quality mance to match these requirements. standards when the individual manuFor initial processes, calipers, facturing steps—starting with cutting micrometers, bench stands with indiand ending with final machining—are cators, thickness gages and other consistently stable. This simple hand tools are requires process-oriented TECH TIPS usually sufficient. But inspection of charac» Air gages effectively meamoving further along teristics, along with fast sure all common types of in the manufacturing feedback when tolerances dimension, and are particcycle, two important have been exceeded, and ularly suited to checking things need to be condocumentation of all dimensional relationships. sidered. First, once tolerprocess data. Whether » Differential air gaging ances tighten, a whole monitoring dimensional combines the necessary new class of gaging is data, surface qualities high resolution and accurequired. Gages must be or form parameters, it is racy with the speed, ease more robust, have the important to understand of use and ruggedness proper design characterhow the processes affect required on the shop floor. istics to fixture the parts the quality of the parts. » Understanding the form properly, and have the Typically, as parts of mating tapers as part proper resolution and move through the manuof process development accuracy to measure the facturing process from is not only important to required tolerances. raw material to final the function of the locking But the second thing product, dimensional toltapers, but also is importo consider is that as erance, surface finish and tant in determining the tolerances get tighter, geometric characteristics proper selection and use surface finish and form become more critical. of dimensional gages.

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QUALITY | October 2011

characteristics begin ch har arac acte ac teeriisttic icss be begi gin gi n to take tak a e up u a llarger arge ar geer portion of the overall tolerance band. It is not uncommon for a form or surface finish condition to use 25% or more of the total dimensional tolerance available. Thus, form and surface errors can combine with dimensional errors and lead operators to make wrong decisions as to part quality. WHY AIR GAGING? One of the tight tolerance dimensional characteristics measured at the end of the process is on the tapers used to match the parts together. Most hip and knee implants use tapers to provide good alignment and to “lock” the components into position. In manufacturing these devices, control of both taper and size determines how well the implants perform over their lifetime. Increasingly, air gaging has become the inspection tool of choice for controlling these critical parameters. Air gaging is fast, easy to use, provides high precision results even under the toughest shop conditions, and can last for years measuring literally millions of parts. Air gages effectively measure all common types of dimension, and are particularly suited to checking dimensional relationships. As an inspection tool, air gaging can measure many

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 Measurements of the stem include the roughness of the polished area found on the proximal portion of the prosthetic femoral stem. This area is subject to close visual inspection for asperities by the orthopedic surgeon. To verify surface and waviness quality of the taper, a contour gage is used to trace the taper in the same measurement. Source: Mahr Federal Inc.

TYPES OF AIR TAPER GAGES Medical implants take a beating and the taper fit between the female and male components is critical. The two pieces have to lock together and sit at the correct height. During manufacture it is common to inspect 100% of parts to ensure the accuracy of both components. This is usually done with differential air gaging, which combines the necessary high resolution and accuracy with the speed, ease of use and ruggedness required on the shop floor. The most common type of air gage taper tooling has two pairs of jets on opposing air circuits, and is designed for a “jam fit” between the part and The machining process may leave influences on the form the tool. If the rate of taper is of a part. Understanding the form of mating tapers as part of process development is important to the function too great, there will be excesof the locking tapers. During the initial manufacturing prosive clearance between the two cess, all part characteristics should be qualified, including surfaces at the small end of the form and finish, as this can influence the design of the taper. If the rate of taper is too gage. Source: Mahr Federal Inc. small, there will be excessive TAPER DESIGN clearance at the large end. For years the taper design of Either situation can reduce the rigidIt is certainly possible to measure choice for orthopedic devices was the ity of the connection, which over time diameter and taper with either a combisimple round taper. It functioned well, can cause the “lock” to fail by becomnation of electronic sensors or coordibut new designs, such as complex taper ing loose and/or rotating. If the taper nate measuring machines (CMMs) with forms employing oblong tapers and angle is correct but the size is incorrect, touch probes. But the air jet can be built special surface finishes have improved then the overall length of the orthopein a precision tool that can be used to product performance. However, these dic assembly will be incorrect and promeasure the part at the point of manunew tapers offer unique challenges to vide unexpected results after implant. facture. This can be done in one fast gage designers. The problem is not just Jam-fit tooling does not measure part measurement with very little operator measuring taper or diameter, but meadiameters, per se. Rather, it displays the involvement. Neither CMMs nor optisuring taper and diameter on parts that diametrical difference at two points on cal gaging have the speed to measure may be only 12 millimeters in diameter the workpiece, as compared to the same 100% of parts on the shop floor, right and 12 millimeters in length. Even on two points on the master. If the differnext to the manufacturing process, parts that are longer, more points freence in diameter at the large end of the while providing immediate feedback on quently need to be measured and more the performance of the process. taper is greater than the difference in data collected. Two conditions most important in diameter at the small end, the upper The reason air gaging is so valucontrolling taper are taper size and jets will see more back pressure than able for orthopedic tapers is the air the lower jets. This will reflect negaangle. Size is controlled by tolerance, jet, the small orifice that emits air to and is, therefore, identical to a cylintive taper, or a larger taper angle. If the begin the physical process of creating drical inside diameter (lD) or outside diameter difference at the small end is a gage. No other gaging sensors are as diameter (OD). Taper angle, on the greater, the reverse is the case and the small or can be placed in such close other hand, can be controlled by at gage will read positive taper. proximity when measuring multiple But because a differential air meter least three different methods: diameters or geometric forms. Small displays diametrical differences only, 1. Included angle or angle per side electronic sensors or eddy current 2. Taper per inch or per foot it will not display the part’s diameter type sensors may approach the size of 3. Controlling two diameters at speciat either location. So while this type of an air jet, but nothing can match their fied datum locations. air tooling provides a good indication economy or ability to work in a wet of taper wear and allows us to predict a and oily shop environment right at the loss of rigidity in the connection, it does All can be measured with air. point of manufacture. jobs faster, more conveniently and more accurately than other gaging methods. In fact, air gaging can be used in some cases to inspect and estimate certain form features on a part. But air gaging also is so precise and provides such high resolution that it can be influenced by the surface finish of the part. Thus, air gaging is not the solution for all shop measurements. It is typically used for applications where the tolerance is fairly tight—usually less than ±0.001 inch—and surface roughness is less than 50 microinches Ra. When these precision conditions exist, as with precision medical tapers, air can be the best solution for the application. But even when there are surface finish issues, special steps can be taken to account for them.

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October 2011 | QUALITY

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MEASUREMENT

For years the taper design of choice for orthopedic devices was the simple round taper. It functioned well, but new designs, such as complex taper forms employing oblong tapers and special surface finishes have improved product performance. Source: Mahr Federal Inc.

The reason air gaging is so valuable for orthopedic tapers is the air jet, the small orifice that emits air to begin the physical process of creating a gage. No other gaging sensors are as small or can be placed in such close proximity when measuring multiple diameters or geometric forms. Source: Mahr Federal Inc.

Figure 1. Jam-fit tooling does not measure part diameters, per se. Rather, it displays the diametrical difference at two points on the workpiece, as compared to the same two points on the master. Source: Mahr Federal Inc.

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Figure 2. A clearance-style air tool makes it possible to measure diameters at known heights (in addition to the change in clearance, as with the jam-fit type). An additional set of jets may be added to inspect for bell-mouth and barrelshape, two more conditions that reduce the contact area between the male and female components. Source: Mahr Federal Inc.

not tell us anything about the taper components’ positioning accuracy. For that, we need a clearance-style air tool in which an air taper ring cavity is sized to accept the entire taper part. Depending on where the part’s reference surface is, the part can be referenced on the end of the taper or on a flange against the top surface of the part. This makes it possible to measure diameters at known heights (in addition to the change in clearance, as with the jam-fit type). An additional set of jets may be added to inspect for bell-mouth and barrel-shape, two more conditions that reduce the contact area between the male and female components. The third type of air taper gage is a cross between the aforementioned styles. This is called a simultaneous fit taper gage. It is basically a jam-fit air tool with an indicator that references on the face of the datum surface. This indicates how far the air tool goes into the part being measured. So while the air gage provides a reading of the taper angle, the indicator provides an indication of the size of the diameters. When measuring a female taper part, if the taper diameter is too large, the gage will go farther into the part. If the diameter is too small, it will not drop into the part as far as expected. SELECTING THE RIGHT GAGE DESIGN Just as there are many manufacturers of taper components, there are many methods for specifying taper requirements. The reference face may be different between manufacturers, and tolerances can be specified in different ways. Depending on the way the assembly goes together, tolerances may be tighter on the taper than on the diameters, or vice versa. Or, there may be a combination of taper tolerances on only one diameter. Thus, the specification on the print is the best guide in choosing which air taper gage design to use. With air gaging, the tooling is made specifically for each different taper application. So it is critical to properly understand the requirements. Even so, the flexibility and benefits are hard to beat. Think about it: air gaging uses a sensor that is 0.050 inch or smaller; sensors can be placed within 0.10 inch of each other and be combined to produce any number of

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Air gaging provides very high resolution. In this case, with the part having a slight two lobed condition, the two jet circuit of the air gage is more than capable of detecting this out of round condition. Source: Mahr Federal Inc.

dimensional and geometric results right on the shop floor. ACCOUNTING FOR FORM Understanding the form of mating tapers as part of process development is not only important to the function of the locking tapers, but also is important in determining the proper selection and use of dimensional gages. For example, when a manufacturing process inherently produces a two lobe condition, a two jet air probe is most apt to pick up these size and form variations. Once known, form deviation can be correlated and understood as a component of actual size variation within the part. If the form analysis had indicated a three lobe or odd number of lobes in its results, then air tooling employing three jets would have been designed for the application. By understanding the form of the part prior to gaging, the best application of the air tooling can be employed.

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Some parts have designer surface finishes that would normally not be conducive to air gaging. But by understanding the nature of the surface and how it reacts to the open air jets, electronic amplifiers and gaging computers can compensate for these surface characteristics and provide excellent calculations of average or maximum diameters. Source: Mahr Federal Inc.

ACCOUNTING FOR SURFACE Measurements of the stem include the roughness of the polished area found on the proximal portion of the prosthetic femoral stem. This area is subject to close visual inspection for asperities by the orthopedic surgeon. To verify surface and waviness quality of the taper, a contour gage is used to trace the taper in the same measurement. This causes complications for the application of air gaging. As noted earlier, a good surface is necessary to use air gaging. In normal use the air jet’s curtain of air covers an area on the surface of the part. This air curtain is restricted by the surface to create the back pressure which is required to do the measuring. On a smooth surface, the difference between the average surface and the peaks, which in the case of an ID part means minimal clearance, is pretty much insignificant. But if the surface

is very rough, the area, or the point at which the back pressure is built up, can be significantly different. This can register on the air gage display and affect the indicated diameter. As long as the surface finish is less than 50 microinches, this offset can normally be ignored. However, even if it is not, if the effect is discovered during process development, the error can be compensated for and the effective diameter shown to the machine operator. Q George Schuetz is director of precision gages at Mahr Federal Inc. (Providence, RI). For more information, e-mail [email protected] or visit www.mahr.com.

QUALITY ONLINE For more information on air gaging, visit www.qualitymag.com to read the following: • “Air Gage Does Double Duty” • “Air Gaging Gets Better with Age” • “Why Air Gaging Still Matters”

October 2011 | QUALITY

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TEST & INSPECTION

The Calibration and Accuracy of

X-ray CT Systems X-ray CT systems must be traceably calibrated to give true metrological performance. BY ANDREW RAMSEY

M

odern X-ray computed tomography (CT) systems can produce extremely detailed images of internal and external features of complex components. Many of these features cannot be measured by traditional metrology methods, as they are hidden inside parts. This makes X-ray CT particularly valuable for high-value parts destined for aerospace and other missioncritical applications. Inspection applications for X-ray CT are diverse, cutting across the automotive, aerospace, energy, medical, electronics and electronics packaging industries. The technique is applicable to a variety of materials,

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including metals, composites and (on suitable systems) single-crystal materials. Accompanying software tools enable analysis of part features against a computer-aided design (CAD) model, either via direct CT data-to-CAD comparisons or through geometric dimensioning and tolerance (GD&T) measurements. And with price points low enough to make it competitive with other techniques, X-ray micro CT is increasingly ready for mainstream metrology. CURRENT TECHNIQUES Like other metrology technologies, X-ray CT systems must be traceably

calibrated to give true metrological performance. Although technical committees are in the process of drawing up EU and ASME calibration standards, there currently is no internationally recognized standardized procedure for calibrating X-ray CT equipment. Instead, calibration must be derived and traced from another metrology method that does have such a standard, for example, a coordinate measuring machine (CMM). There are currently two main methods of calibrating CT data at present: • Traceable calibration pieces • Combined CMM and CT systems. It is recommended to use traceable calibration pieces, a lower-cost, simpler and more flexible calibration technique than combining CMM and CT systems in one.

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Quickly find burrs and other defects!

A 3-D view (left) and 2-D slice through a fuel injector nozzle generated by an 8-minute X-ray CT scan. CT data can be compared with the CAD model of the part or used for GD&T analysis. Source: Nikon Metrology

COMBINED CALIBRATION Users of the combined calibration method must first purchase a system consisting of both an X-ray CT system and a CMM—a relatively expensive proposition. Because the CMM is part of the system, its electronics must be protected from the X-rays. For this reason the CMM cannot be used when the X-ray CT system is in use. This reduces overall system flexibility and can complicate inspection routines. The combined calibration method relies on use of the CMM to find a physical surface based on CMM settings before location of a surface based on the threshold of the X-ray CT scan. These two readings must then be calibrated to each other before the system can be used. The technique treats internal and external surfaces identically, and thus fails

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TECH TIPS » Modern X-ray computed tomography (CT) systems can produce extremely detailed images of internal and external features of complex components. » There are currently two main methods of calibrating CT data at present: traceable calibration pieces and combined CMM and CT systems. » The combined calibration method relies on use of the CMM to find a physical surface based on CMM settings before location of a surface based on the threshold of the X-ray CT scan. » The preferred calibration method relies on having a traceable calibration piece consisting of a number of spheres, which are chosen to have scale and X-ray properties similar to those of the test piece.

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October 2011 | QUALITY

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TEST & INSPECTION

Scaled CT data matches actual part dimensions and, combined with a true local surface determination, gives a traceable calibrated 3-D CT model. Source: Nikon Metrology

to account for beam hardening or scattered X-rays. Combining use of X-ray CT and CMM not only is relatively expensive and inflexible; it also can lead to compromises in manipulator positioning

The preferred method relies on a traceable calibration standard consisting of a number of spheres. Measuring the samples with a calibrated CMM lets users derive center-to-center distance of the spheres. Source: Nikon Metrology

simple. It relies on having a traceable calibration piece consisting of a number of spheres, which are chosen to have scale and X-ray properties similar to those of the test piece. Measuring the calibration samples

Inspection applications for X-ray CT are diverse, cutting across the automotive, aerospace, energy, medical, electronics and electronics packaging industries. because the CMM must be shielded from X-rays. Thus, combined systems are more complex, operators require additional training and can have longer scan times than systems using the preferred method. Combined systems also require CMM infrastructure—a granite bed and articulating arm—that further increase the cost, mass and complexity of the system. THE PREFERRED METHOD In comparison, the preferred calibration method is relatively low-cost and

with a calibrated tool such as a CMM allows operators to derive the centerto-center distances of the spheres. The X-ray threshold used to determine surface position in the X-ray CT volume data is irrelevant to the center-to-center distances. Thus operators can calculate voxel size in the CT data with accuracy of approximately 0.1%, more accurately than system calibration of approximately 1%. The only caveat here is required use of spheres—use of a linear threshold dimension would compromise accuracy.

Operators can then scale the CT data exactly so that it matches actual part dimensions and set the voxel size of the 3-D model to the value found from the traceable calibration. When combined with a true local surface determination, this will give a traceable calibrated 3-D CT model. MULTIPLE BENEFITS In the preferred method, operators need not own a CMM. An external CMM or similar metrology equipment can be used to traceably measure the calibration pieces. Measurement can be performed offline at any certified lab or equivalent at regular intervals. The X-ray system can be used to take the CT as required, and the CMM used for calibration is available to make other measurements of other parts at the same time. Also, the method treats both the traceable calibration piece and the test object in the same way—that is, the surface is found from the CT scan. This approach provides confidence that the same surface has been located. Internal and external surfaces

ATTRIBUTES OF CURRENT X-RAY CT CALIBRATION METHODS PREFERRED METHOD

COMBINED METHOD

• Low cost; no need to purchase a CMM

• High cost; must purchase CMM and X-ray CT

• Flexible—CMM and CT can be done on different objects at the same time

• CMM cannot be used (must be shielded) when X-ray machine is on

• Relies on CT consistency; objects calibrated from X-ray results

• Assumes that CMM and X-ray surface are the same

• Finds position of surface using gradients

• Assumes internal surface is the same as external surface

• Simple system; just does one job

• Relatively complex system

• Low mass—does not require the CMM mass

• Heavy—requires both CMM and CT systems

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are found using local thresholds and gradients, minimizing or negating the effect of beam hardening and scattered X-rays. There also is something to be said for having one apparatus designed to do a single job and do it well. In the preferred method, the X-ray CT system performs no functions that are not key to fast, accurate industrial computed tomography. Systems require no precision granite bed or large arm like a CMM would, so mass is lower. This results in faster and more accurate measurement. APPLICATION EXAMPLES The preferred method of X-ray CT calibration has been proved in real-world applications. For example, in turbine blade inspection, four slices are taken through the blade at different heights relative to the datum. The full-resolution scans of the turbine blade samples collected more than 8,000 projection images through 360 degrees. At least one major aerospace manufacturer has concluded that X-ray CT metrology is accurate through the results of numerous trials. Using a minimum/maximum wall thickness measurement tool in the system’s image analysis software, operators can measure the wall thickness of the turbine blades at desired locations. Blind trials have been carried out on diesel engine fuel injector nozzles to prove its case for the accuracy and utility of industrial X-ray CT.

For inspection of wall thickness of super-alloy aerospace turbine blades, X-ray CT was used to take multiple slices through the blade section at various heights from the datum. Source: Nikon Metrology

Accuracy of the shape and location of the tiny holes in automotive and diesel fuel injector nozzles is one of the keys to more efficient combustion and

Andrew Ramsey is a CT Specialist/X-Ray Centre of Excellence at Nikon Metrology Inc. (Brighton, MI). For more information, visit www.nikonmetrology.com.

In the preferred method, the X-ray CT system performs no functions that are not key to fast, accurate industrial computed tomography. thus improved fuel efficiency, so hole size, location and form is controlled as tightly as possible. An 8-minute X-ray CT scan of a diesel fuel injector nozzle can produce both 3-D data and 2-D slices through the component for GD& T measurement plus comparison to CAD data. Q

QUALITY ONLINE For more information on X-ray, visit www.qualitymag.com to read the following: • “2-D vs. 3-D: X-Ray Systems Go Under the Microscope” • Quality 101: “X-Ray Tomography: The Basics” • “X-ray Machine Goes Big”

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October 2011 | QUALITY 9/14/11

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MANAGEMENT

The Lasting

Legacy OF THE MODERN QUALITY GIANTS As Quality Magazine celebrates its 50th anniversary, we take a look at some of the quality gurus who have made a significant impact on the world through their contributions to improving not only businesses, but all organizations. BY JIM SMITH

C

ertainly there have been many quality gurus who have left their mark on industry and society as a whole. This article focuses on six people, three of whom I am proud to say that I have known professionally and personally, who had a profound impact on the quality movement. Subconsciously, I may have placed these luminaries in priority order so this list maybe one-sided and can be argued from various perspectives. As the author, I have taken some liberties but many experts will likely concur with those appearing here but the order may change, depending on individual experiences. WALTER A. SHEWHART (1891-1967) Walter Andrew Shewhart was a giant among giants in the quality movement during the first half of the 20th century. While working for Western Electric located in Hawthorne, IL, his groundbreaking work focused on reduction of

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variation and charts. His work altered the course of industrial history, led a quality revolution and launched the quality profession. Shewhart defined the problem of process variability in terms of assignable and chance causes. On May 16, 1924, Shewhart prepared a memorandum of less than one page in length and forwarded to his manager, George Edwards, who later became the first president of American Society for Quality Control. This memorandum set forth the essential principles of controlling variation through the application of control charts. Shewhart’s principle was that bringing a process into a state of statistical control would allow the distinction between assignable and chance cause variations. By keeping the process in control, it

would be possible to predict future output and to economically manage processes. This was the birth of the modern scientific study of process control. Shewhart has often been referred to as the father of statistical process control. In 1931, he published his watershed work, “Economist Control of Quality of Manufactured Product.” It challenged the inspection-based approach to quality and introduced the modern era of quality management. Up until this time, statistical process control was largely a Bell Telephone quality tool. Shewhart’s book, however, popularized statistical control and a its use then spread throughout industry. th From the 1930s forward, Shewhart’s interests w expanded from industrial e quality to wider concerns q in science and statistical inference. Shewhart was in at a the core of a group of people who were destined p to become famous in their th time. This group included Harold Dodge and Harry Romig, known for their work on product sampling plans. Joseph M. Juran worked at the Hawthorne Plant and Bell Laboratories for several years and worked closely with Shewhart.

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October 2011 | QUALITY

41

MANAGEMENT W. Edwards Deming worked as an intern at the Hawthorne Plant where he became interested in Shewhart’s work. Shewhart and Deming had a long relationship of collaboration. Deming continued to champion Shewhart’s ideas, methodologies and theories throughout his career. While working with Japan, Deming further developed some of Shewhart’s methodological proposals of scientific inference, which had been named the Shewhart Cycle and was represented by the plan-do-checkact elements. During the 1990s, Shewhart’s work was rediscovered by a new generation of industrial engineers and managers, and this time these concepts were repackaged and incorporated into the Six Sigma approach. Shewhart believed that statistical theory should serve the needs of industry and society as a whole. He challenged the norms of his day and showed manufacturers a better way that revolutionized industry. Shewhart has often been referred to as the father of statistical quality control because he brought together the disciplines of statistics, engineering and economics. Upon his death in 1967, there were a multitude of commentaries from many who were themselves important figures in the development of the quality field. An excerpt from a speech by the chairman of the committee that awarded the first ASQ Shewhart Medal captured Shewhart’s character in the follow words: “Shewhart’s legacy lives in mementos of him—a simple bowl and some numbered chips, a bronze medal, some books and writings. It lives in the succession of other prominent individuals he influenced, and it lives in the society of professionals who carry on the work he started.” JOSEPH M. JURAN (1904-2008) Joseph Moses Juran had a profound impact on not only the lives of countless individuals, but on nations of the world as he spread the gospel of total quality. No other person was able to capture the essence of quality as a total effort. Juran has been called the father of quality and referred to as the greatest quality giant of the 20th century. Perhaps, more importantly, he is recognized as the person who influenced the addition of the human dimension to quality, broadening it from its statisti-

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cal origin to the more comprehensive total quality management. Juran pushed for the education and training of managers. His thought was that human relations problems were the ones to isolate and resolve. Resistance to change was more cultural and the root cause of quality problems. My personal exposure to Juran began with one of his articles more than 35 years ago. As a young quality engineer, I was part of team charged with bringing to my company unique quality approaches. Juran consented to visit with our senior management and share his thoughts. I had the privilege of meeting him during one of his visits, and after more than 30 years, our company is still applying some of his recommendations. I was able to meet Juran on other occasions, but during our first meeting I was inspired to sustain a career in quality and become involved in American Society for Quality. Through a journey of studying and learning about quality from a variety of people, I became a Juranite—a disciple of his theories and practioner of his principles on quality. He did not just teach statistics. In fact, he did not think of himself as a statistician, but more dedicated to the total quality approach. Through Juran’s influence it became evident that the human side of quality was just as important as the technical side. Juran’s life is like a Horatio Alger story. His humble start in life gave no indication to the success and notoriety he would achieve during his life. In 1924 he accepted a position in the inspection group at Western Electric, a division of AT&T, in Hawthorne, IL. He rose to inspection division chief in just five years. During this time he wrote the first known text on statistical quality control—and the ancestor of today’s widely used “Western Electric Statistical Quality Control Handbook.” Little did he know at the time the decision to work at Western Electric would set him off on a more than 75-year career in quality. He would work with a virtual “who’s who” in quality. People such as George Edwards, Harold Dodge, Harry Romig

and Walter Shewhart were instrumental in shaping his ideas and his future. During World War II, Juran served the Department of Defense (DoD) as assistant administrator of the LendLease Program. After the war w he did not go back to Western Electric but went W forward to create history fo and a a legacy for generations of o quality professionals. In 1946 Juran, along with w several other notables, founded the American fo Society for Quality S Control. He developed C what w has been called the foremost influential course fo on quality. His “managing for quality” has been taught to thousands of people in almost every country of the world. In 1954 he conducted seminars for Japan’s senior and middle managers, explaining the roles they had to play in promoting quality. Juran was invited back many times and his teachings were so inspirational to the Japanese people that a temple was named in his honor. He also was honored with Japan’s highest award that can be given to a non-Japanese, the Order of the Sacred Treasure. It was awarded in recognition of his contribution to “the development of quality control in Japan and the facilitation of U.S. and Japanese friendship.” Juran’s process of developing ideas was gradual. Top management involvement, the Pareto principle (which could easily have been named the Juran principle), the need for widespread quality training, the definition of quality, the Juran Trilogy, the project-by-project approach to improvement—these are some of the ideas for which he is best known and all emerged gradually. The first edition of his classic book, the “Quality Control Handbook,” first released in 1951, contained about 100 pages and his fifth edition contained more than 1,900 pages. (The 6th edition was recently released with much acclaim.) His handbook is still widely considered to be the bible on quality and was instrumental in becoming core elements in the body of knowledge for ASQ certified quality engineers. Juran founded the Juran Institute in 1979 with the aim of increasing awareness of his theories and principles. It was through this institute

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MANAGEMENT that the widely acclaimed video series “Juran on Quality Improvement” was produced. He continued to deliver exceptional contributions well into his 90s. He played a part in development of the Malcolm Baldrige National Quality Award, which has led a revolution of organizational improvement. Like Shewhart, much of Juran’s work was rediscovered by engineers and managers in the 1990s. His principles of improvement coming project-byproject led by trained facilitators and leaders were incorporated into the Six Sigma approach. Juran was one of those rare individuals whose collective work spans generations to make a sustained impact on society. His groundbreaking work in quality management and leadership was the catalyst that transformed industries. Shortly before his death Juran said, “My job of contributing to the welfare of my fellow man is my great unfinished business.” He is truly missed and it is doubtful there will be anyone who will soon follow in his footsteps. Juran was truly the “architect of quality.” WILLIAM EDWARDS DEMING (1900-1993) W. Edwards Deming was an American statistician, author, lecturer, professor and management consultant. Perhaps he is best known for his work in Japan after World War II when the Department of Defense (DoD) asked his help in the rebuilding of their industries. From 1950 forward, Deming taught management how to improve design, product quality and testing through various methods, including the application of statistical application. Deming’s great legacy was that he opened the way for quality and statistical thinking in Japan, and later to American companies such as Ford Motor Co. Deming made a significant contribution to Japan’s reputation for innovative high-quality products and its emergence as an economic power. He is regarded as having had more impact upon Japanese manufacturing and business than any other person of non-Japanese heritage. Deming is considered a folk hero in Japan because of the impact of his work. His influence was so significant that it is considered to have significant influence on Japan’s third wave of industrial revolution. The Japanese

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QUALITY | October 2011

government showed their appreciation for his work by honoring Deming with an imperial award, the Order of the Sacred Treasure, and establishing an award in his name, the Deming Prize. His accomplishments while working with the Japanese resurging industries could hardly have been predicted but his inspiration for excellence was set in place years before. While working on his Ph.D. at Yale in mathematics and physics, he had internships at Bell Telephone Laboratories, a division of AT&T. Deming found great inspiration in the work of Walter Shewhart, the originator of the concepts of statistical control of processes and the related technical tool of the control chart. Shewhart’s idea of common and chance causes of variation led directly to Deming’s theory of management. He realized that these concepts could be applied not only to manufacturing processes but also to the processes by which organizations are led and managed. This insight was significant as it made possible Deming’s influence on the economics of the industrialized world after his work with the Japanese. Despite being considered a hero in Japan, he still struggled to get his ideas accepted by American businesses. The watershed event that would change all that and catapult Deming into the American scene was the 1980 NBC video whitepaper titled, “If Japan Can, Why Can’t We?” This documentary was about the increasing industrial competition the United States was facing from Japan. As a result of the broadcast, demand for his services increased significantly, and continued throughout the world until his death at the age of 93. Ford Motor Co. was one of the first American companies to recruit Deming to help jump-start their quality movement. To management’s surprise, Deming’s first order of business was not to talk about quality but about management. Deming stressed that 85% of all problems were managementcaused. As Ford implemented more and more Deming principles, quality and profits improved. In a letter to AutoWeek Magazine, Donald Peterson,

then-Ford CEO, said, “We are moving toward building a quality culture at Ford and the many changes that have been taking place here have their roots directly in Dr. Deming’s teachings.” In his book, “Out of Crisis,” Deming’s theory of management presented his famous 14 Points for Management. Management’s failure to plan for the future brings about loss of market share, which results in the loss of job security. He stressed that management must be judged not only by quarterly profits, but by longer-term plans to stay in business, protect their investment, ensure future shareholder dividends, and provide more m employment through improved products and serim vices. Deming commented, v “Long-term commitment “ to new learning and new philosophy is required p of o any management that seeks transformation. The s timid and the fainthearted, ti and a the people that expect quick results, are doomed q to disappointment.” Deming left a legacy that lives on in his documented works. He founded the W. Edwards Deming Center for Quality, Productivity and Competitiveness at Columbia Business School to promote operational excellence in business through the development of research, best practices and strategic planning. His value and benefit to society can be seen in his System of Profound Knowledge, which is the basis for application of his famous 14 Points for Management. Deming taught that by adopting appropriate principles of management, organizations can increase quality and simultaneously reduce costs. The key is to practice continual improvement and think of manufacturing as a system, not as separate initiatives or elements. KAORU ISHIKAWA (1915-1989) Kaoru Ishikawa was a Japanese icon, university professor and inf luential quality management innovator. The lifetime work of Ishikawa was extensive and had a profound impact on a worldwide scale. He wrote 647 articles and 31 books, including two that were translated into English: “The Guide to Quality Control” and

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“What is Total Quality Control? The Japanese Way.” After World War II, Japan needed to transform its industrial sector, which was then perceived as a producer of cheap toys and poor quality cameras. It was Ishikawa’s ability to mobilize the Japanese government and people toward a specific common goal that was largely responsible for Japan’s quality-improvement initiatives. How was he able to do this? Ishikawa was perceived as wise, insightful and able to get people to focus on the very root of problems. Ishikawa integrated and expanded the management concepts of Deming and Juran into the Japanese system of quality management. His ability to interpret the primary concepts and translate into a system of improvement techniques and strategies was critical to the Japanese success. Ishikawa, in conjunction with the Japanese Union of Scientist and Engineers (JUSE), introduced the concept of quality circles. This concept began as an experiment to see what effect the “leading hand” at the worker level could have on quality. It was a natural extension of training that was taking place at other levels of an organization—the top and middle managers having already been trained by Deming and Juran. Ishikawa believed strongly that all workers must be involved in quality improvement and that teams provided the greatest avenue to participation. People’s ability to offer suggestions to improve processes and products would be maximized by providing training in basic problem solving techniques. A simple concept today, but it was unique at the time. Quality circles would soon become very popular and form an important link in a company’s total quality management system. At one point there were 1 million active quality circles in Japan, involving more than 10 million people. He was at the forefront of the Japanese total quality control movement. To reduce confusion between Japanese and the western-style approaches, he called the Japanese

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method companywide quality control (CWQC). CWQC involved participation of workers from the top to the bottom of the organization and from the start to the finish of the product life cycle; therep fore, fo the approach justifies its it name. Ishikawa became the chairman of the editoc rial r board of the monthly Statistical Quality S Control. Becoming so C well-known and estabw lished, Ishikawa was li involved in international in standardization activities s exposing him to other key concepts and initiatives. He is well known for developing the concept for the fishbone diagram, also known as the Ishikawa or cause and effect diagram that is used by teams to improve their performance in determining potential root causes of their quality problems. The cause and effect diagram became one of the seven basic quality tools and is utilized thoroughly by teams and recognized around the world for its contribution to improvement. Perhaps the most dominant leader in JUSE, Ishikawa also served as president of the Japanese Society for Quality Control. He co-founded and served as president of the International Academy for Quality. His approach to reviewing the quality performance of Japanese companies formed the model HewlettPackard used to conduct internal quality reviews. Later, that approach served as a role model for the site visits conducted by the board of examiners for the Malcolm Baldrige National Quality Award. Upon Ishikawa’s 1989 death, Juran delivered this message: “There is so much to be learned by studying how Dr. Ishikawa managed to accomplish so much during a single lifetime. In my observation, he did so by applying his natural gifts in an exemplary way. He was dedicated to serving society rather than serving himself. His manner was modest, and this elicited the cooperation of others.” Juran has been called the father of the quality movement. If this is so, then Ishikawa could be called the grandfather of the quality movement.

He was wise and openly shared his insight for the benefit of all. He was able to get to the point of a problem, no matter how complex, and offer sound advice. Isn’t this what a benevolent grandfather does? ARMAND V. FEIGENBAUM (1922- ) Armand Vallin (Val) Feigenbaum is an American quality expert, academic, innovator, author, benefactor and businessman. He certainly is considered a quality guru but his life’s work is much broader than that title indicates. He has been a role model for managerial innovation and its implementation. He was one of the first engineers to be able to speak in the language of management by using financial performance as an indicator of poor quality. Throughout his career, Feigenbaum was able to refine his business theories to demonstrate the economic relationships whereby quality drives commercial performance. Early practitioners of quality theories and principles focused on inspection and statistical sampling or the use of statistics for process control. Feigenbaum, however, was the first to define a systems engineering approach to quality. With more than 30 years of handson managerial experience and serving as quality champion at General Electric (GE), Feigenbaum was able to develop his system theories. He rose rapidly into increasing levels of responsible positions. While GE’s global quality focus expanded, Feigenbaum made many international contacts with leading businesses in Europe and Japan. Feigenbaum’s ideas are contained in his now famous book “Total Quality Control,” first published in 1951 under the title “Quality Control: Principles, Practice, and Administration.” This book has been translated into more than a score of languages and the fifth edition was recently released. This book and his related contributions is why Feigenbaum has been called the father of quality management and is widely recognized as a quality guru. Total quality control, known today as total quality management (TQM), is one of the foundations of modern management and has been widely accepted as a viable operating philosophy across various industry sectors.

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MANAGEMENT The integration of previous concepts and methods of quality control into a systematic discipline are what made his work so significant. Many of his initial contributions were not readily recognized by senior management as critical success factors for sustained business growth. That changed with the NBC documentary, “If Japan Can, Why Can’t We?” which was broadcast on June 24, 1980. Coincidently, the release of the third edition of “Total Quality Control” happened around this time and caused renewed focus on his principles. Feigenbaum served a pivotal role in the history of the quality movement. Along with Juran and Deming, he established the intellectual framework for quality as a discipline worthy of senior management’s attention. While the quality movement had previously focused on production processes and product quality using statistical tools and analysis methods, the extension of quality into all areas of business, including the service and public sectors, is Feigenbaum’s lasting contribution. By encouraging a systems approach, he focused organizations on building an understanding of the effects of the flow of their business operations and how one operation had subsequent impact on downstream operations. This systemic linkage among processes was the breakthrough thinking for Japan’s just-in-time management and Ishikawa’s companywide quality control. Feigenbaum’s second influential concept was financial accountability which he introduced through his emphasis on the impact of the cost of poor quality. He studied the economic effects caused by poor quality performance and characterized quality costs as the costs of prevention, appraisal, as well as internal and external failure. Feigenbaum was the first to introduce the concept of the “hidden” plant. The idea that so much extra work is performed in correcting mistakes that there is a hidden plant within any factory or organization. This work encouraged Philip Crosby’s application of “zero defects” and Feigenbaum’s cost of poor quality

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indicator as the business measurement standard to assess nonconformance to customer requirements. Many managers misunderstand one of the more popular sayings attributed to Feigenbaum, “quality is everybody’s job.” What many don’t realize is that Feigenbaum intended this concept to be about establishing accountability for quality. Because quality q is everybody’s job, it may become nobody’s job. The b idea id that quality must be b actively managed and have visibility at the highh est e levels of management. Feigenbaum continues to expand his theories and a principles to a worldwide audience. He cow founded, along with Dr. fo Kaoru Ishikawa of Japan K and Walter Masing of Germany, the International Academy for Quality, an organization that continues to be dedicated to advancing the understanding and use of principles, techniques and tools to benefit society at large. Along the way, Feigenbaum steered the structure of the Malcolm Baldrige National Quality Award as a member of its inaugural board of overseers, the group that helped create an operational definition of total quality in terms that can be broadly applied throughout society. For his significant contributions, he received the National Medal for Technology and Innovation in September 2008 from President George W. Bush. When history judges the breakthrough ideas and thought leaders of the 20th century, Feigenbaum will be noted for his enduring contributions. He has earned a unique place in the history of engineering through his definition, advancement and execution of his quality and managerial principles. PHILIP B. CROSBY (1926-2001) Philip Bayard Crosby was a legend in the quality movement and was considered one of the leading authorities on the subject. He was a businessman, quality professional, author, trainer, philosopher and management consultant throughout his storied career. After serving in World War II and Korea, and a brief stint as a podiatrist, Crosby began his career as a quality

professional. After working as a test engineer at Crosley Corp and a reliability technician at Bendix Corp., he joined Martin Marietta, now Lockheed Martin, in 1957 as a senior quality engineer. This began the development of his zero defect concepts and his writing and speaking on this topic. In 1965, Crosby joined International Telephone and Telegraph (ITT) as the vice president of quality. During the 14 years with ITT, he worked with many of the world’s largest industrial and service companies, implementing his pragmatic management philosophy, and found that it worked. Juran, Deming and Feigenbaum were considered the brains, the academics, of the quality revolution. Where Crosby excelled was in finding a terminology for quality that everyone could understand. Like Fredrick W. Taylor, also an influencer of Juran, Crosby’s ideas came from his experiences on an assembly line. He focused on zero defects, not unlike the focus of the Six Sigma quality movement (although, even 6 sigma quality produces 3.4 ppm, which is not zero). Crosby was quick to point out, however, that zero defects is not something that originates on the assembly line. To create a manufacturing process that has zero defects, management must set the tone and atmosphere for employees to emulate. If management does not create a system by which zero defects are clearly the objective, then employees are not to blame when things go astray and result in defects occurring. The benefit for organizations of such a system is a dramatic decrease in wasted resources and time spent producing goods that customer’s do not want. Crosby published 14 books, all of which were best sellers. His first book, “Quality is Free,” has been credited with beginning a quality revolution in the United States and Europe. It has been translated into 15 languages and sold more than 2.5 million copies. All his books, including his other keynote book, “Quality Without Tears,” were easy to read, so people read them. He popularized Feigenbaum’s idea of the cost of poor quality, that is, figuring out how much it really costs to do things badly. Crosby showed managers everywhere that doing things wrong made

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Jim L. Smith has more than 45 years of industry experience in operations, engineering, research and development and quality management. You can reach Jim at [email protected].

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costs skyrocket. More importantly, he showed that management was the root cause of these problems. The book set off a revolution in corporate thinking because it shifted the responsibility for the quality of goods and services from the quality department to the corporate boardroom. To Crosby, there was no such thing as a quality problem. Systems, individuals, processes or departments cause the problems. This was unique thinking. In a meeting to discuss a problem, a department manager brought up a recent quality problem causing much difficulty. After correcting the manager by saying there was no quality problem, the manager became upset and asked, “then what are we meeting for?” When Crosby said “to discuss the engineering problem,” it spurred much debate but it drove the organization to an enlightened transformation and an improved quality culture. Crosby left ITT to form his own company, Philip Crosby Associates, where he spread the quality gospel through training and management consulting. He went on to be recognized by corporations around the globe as a guru of quality management, and a business philosopher and innovator who changed the way organizations seek to achieve greater efficiency, reliability and profitability. In addition to his zero defects concept, Crosby left us with his Four Absolutes of Quality Management, the Five Characteristics of an Eternally Successful Organization, and his 14 Steps to Quality Improvement. Crosby was a prime mover to promote the expansion of the quality concepts, theories and principles. First as head of quality from the global behemoth ITT and then as one of the most highly respected and sought-after quality management consultants and educators, he played a key role in quality improvement. Crosby’s legacy continues to live on in better quality in thousands of organizations across the globe. Upon Crosby’s death, a noted quality professional had this tribute, “He was one

October 2011 | QUALITY QLT10114Comtor.indd 1

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MANAGEMENT

Calibration CAN BE RISKY BUSINESS When it comes to calibration requirements, make sure you get what you need. BY HARRY C. SPINKS

R

Calibration of test, measurement and isk management is critical in every inspection equipment is critical to manbusiness, particularly in today’s ufacturing. Measurement equipment volatile economy. Failure to assess may be embedded in processing equippotential risks and take action to mitiment and is used to verify that processes gate them can result in financial loss, are running within acceptable paramharm to people or the environment, eters. Calibrated inspection equipment and ultimately failure of is used to ensure that the business. TECH TIPS materials, components Calibration is one » Calibration is one area and end items are within area where risk managewhere risk management is specifications after a proment is needed to reduce needed to reduce liability cess is completed. liability and expenses, and expenses, whether you What are the risks whether you have an have an internal calibration department or outassociated with calibrainternal calibration source calibration. tion and what can be department or outsource one to mitigate or reduce calibration. In either » As a customer of a calibrathose risks? case, one must detertion supplier, document mine the risks associated your equipment’s calibration specifications and link Calibration Risks: with the equipment and them to the product • Overdue calibration— its calibration. In some or process. condition unknown industries this is more • Failure—out of tolercritical, such as pharma» As a provider of calibration services, request that your ance (impact to ceuticals, medical device, customers provide their product/process) aerospace and defense. requirements for each piece • Used outside specs/ Depending on the of equipment. range—unintended company, improperly purpose calibrated equipment • Incorrectly calibrated—wrong calicould impact the quality of the prodbration standard, procedure, specifiuct or service they provide, resulting cations, technician training in potential harm to people or the • Over calibration—calibrated too environment. Product may need to often, too much be recalled or services performed • False failure—fails calibration, but is again resulting in a financial impact actually in tolerance to the company. Unique ID

Make

Model

Serial #

Description or Nomenclature

Result: • Business risk—increased scrap, expenses, reduced productivity and missed schedules • Process risk—defective product produced and enters supply chain and customer impact • Safety risk—potential harm to people or environment As an auditor with a calibration background, I have found many instances where the business did not understand what they received when their equipment was calibrated. What was performed was different from what they needed, but they did not know it. They had a calibration certificate and assumed that the equipment was properly calibrated—in some cases it wasn’t. Auditors have a basic motto: • Say what you do (documents). • Do what you say (action). • Prove that you did it (data records). When it comes to calibration, the motto is: • Say what you need (document requirements). • Ask for it (action). • Prove that you got it (data records). Sounds rather simplistic, but it is really very important. Most companies ask for what they want—their equipment calibrated. They leave the requirements up to an internal or external calibration provider. Many Parameter

Range

Accuracy

Example table of equipment with calibration specifications

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QUALITY | October 2011

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tions and what can be done to reduce the risk. CALIBRATION CUSTOMER As a customer of a calibration supplier you need to document your equipment’s calibration specifications and link them to the product or process. At the least, ensure that the manufacturer’s specifications meet your needs and document it.

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WHAT’S HAPPENING? Few companies have metrology engineers, metrologists or senior calibration technicians on staff. They rely on others to determine the calibration specifications. Who are these others? It depends on the company. In some companies they may be inspectors, technicians or engineers. Very few engineers are trained in metrology and even less are trained in calibration. The result can be calibration specifications which are unrealistic for the equipment (better than the manufacturer’s specifications). Or they do not take into account all of the measurement components that make up the measurement system. Normally, they are just looking at range and accuracy specifications and not considering the measurement uncertainty of the system. When outsourcing calibration, a company is relying on the supplier to perform the calibration correctly. But what is correct? The calibration supplier will probably use their own procedure since most calibrations do not have standardized procedures. They may use the same calibration process as the manufacturer, if one is available. Or they may obtain procedures from the Government-Industry Data Exchange Program (GIDEP, www. gidep.org) which are contributed by the government (military services) and commercial industry.

Have you documented your equipment’s calibration specifications and linked them to the product or process? Have you communicated them to the calibration supplier? If not, how does the calibration supplier (internal or external) know what you need?  While there are many risks and risk management processes, we are just going to look at calibration specifica-

  

manufacturers outsource some or all of their calibration activities since this is not one of their core competencies. They receive a calibration certificate and a bill for the services and assume that the calibration and the calibration certificate are what they need. Often this is not the case. For companies with an internal calibration department, one of the engineering groups may take their process requirements and divide by 4 to obtain a 4:1 test accuracy ratio. If the process control requires ±1.0 psi, they assign a calibration accuracy of ±0.25 psi (wishful thinking specs). This would be fine if the gage were rated by the manufacturer for this accuracy. This leads to false failures and extra work when the gage fails to meet the assigned specification but is within the manufacturer’s specification.

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MANAGEMENT To determine the calibration requirements, form a team. The roles of the team are engineering (manufacturing, quality, and/or R&D), customer (production or manufacturing) and metrology (calibration). If all of the equipment is commercial, off-the-shelf, then you should be able to use the manufacturer’s specifications. You still need to verify that the equipment specifications meet your process needs before purchasing it, not after. If the equipment is custom-built, there is more work to do. Identify the measurement components of the system and their specifications, from the manufacturer. Determine how these devices will be calibrated. Be sure to design calibration capabilities into the equipment before you build it or you will delay implementation when the equipment has to be modified so it can be calibrated. How to combine the accuracies of the components in the system is more complicated. You’ll need a metrologist or someone with measurement systems assurance experience to help with this.

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QUALITY | October 2011

Create a controlled form for recording the equipment calibration specifications whether it is in a database or on paper. Be sure to have a process for change control that includes all the members of the risk assessment team. Finally, communicate the requirements to your calibration supplier if they were not a part of the team. CALIBRATION SUPPLIER As a provider of calibration services, you need to request that your customers provide their requirements for each piece of equipment. If you cannot do this electronically, then use paper. You can request it once and maintain it in your system, or request that the customer provide this information with each request for calibration. This can be a challenge for a third-party calibration supplier as some customers just want their equipment calibrated. Sometimes all the supplier receives is a box of gages with no purchase request or identification. The supplier calibrates the gages and expects the customer to verify that it meets their needs.

When the services do not meet the customer’s requirements, it can result in rework and loss to the service provider. Having documented requirements may take more effort to obtain, but will save time and money in the long run. It also may improve customer relations and enable you to keep the customer. Too many issues and the customer may find another supplier. RULES FOR CALIBRATION REQUIREMENTS Rule 1. Gages cannot be calibrated to an accuracy better than that specified by the manufacturer. Over time you may collect sufficient data to show that the gage was consistently within a lesser tolerance than the manufacturer specified. However, it is not good practice to use the gage as if it has a better accuracy (smaller tolerance). Just because the opertaor needs the gage to be ±1% does not mean it will consistently meet that accuracy when the manufacturer gave it a ±5% accuracy. Rule 2. Precision of the gage is built into the manufacturer’s specifications.

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BALL BAR - DUMBELL Do not try to prove precision. You are really determining the repeatability of the measurement process. Think gage repeatability and reproducibility (gage R&R). This has value for critical measurement systems and for measurement systems analysis if you require that level of detail. Rule 3. Do not trust the specifications found on the Internet. They may be catalog or marketing specs, not the real specifications. Get the specification sheet from the manufacturer. Call them if you have to. For example, a temperature chart recorder may be advertised as having a 1 C accuracy. It will meet it, if you use signal injection to provide the input instead of a temperature probe. However, the paper chart will usually have an accuracy of 2 C due to the mechanics of the pen and chart. After connecting a temperature probe to the chart recorder the measurement system (probe + chart recorder electronics + paper chart) will have an accuracy greater than 1 C (a combined worse accuracy depending on each component in the system). So, the chart recorder accuracy will never equal 1 degree. Rule 4. Establish a written agreement with the calibration provider. This may be a purchase agreement, service level agreement or a contract. Put the agreement in writing and make sure that you and the supplier understand your respective responsibilities. Include an out of tolerance notification procedure in the event your equipment or the supplier’s calibration standard is found to be out of tolerance. Rule 5. Document the equipment’s calibration specifications in a controlled system. Identify the parameter, range, accuracy, etc. Provide this information to your calibration supplier and verify their calibration certificate meets the requirements you provided. For example, consider an environmental chamber (oven). The customer has an oven and needs to monitor temperature. They use a chart recorder to continuously monitor the temperature. The chart recorder has a digital indicator and a paper chart (circular in this case). The calibration provider gives the customer a calibration certificate with multiple temperatures. What the customer does not know is that the provider disconnected the chamber’s temperature probe and signal injected the chart

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recorder. Then the recorded the temperature from the digital indicator on the recorder. What’s missing? The calibration data for the temperature probe and the chart. The customer received a calibration certificate and thought their chamber was calibrated, but it wasn’t. Rule 6. Verify you received what you asked for. One concern with providing the supplier with your requirements is getting those requirements to the technician that performs the work. Talk to your supplier and find out how those requirements will be communicated to the technician and verified by the supplier’s quality person before returning the gages to you. Compare the calibration certificate to the calibration requirements—they should match. If not, contact your supplier and find out what went wrong. Be sure to keep a document trail of the issue in case it happens again. BOTTOM LINE If you do not know what calibration specifications you need, get help figuring it out or your financial bottom line could be adversely affected. It is possible to save money if you find out that you have been calibrating equipment that does not need it. You may be thinking that if you have not had a problem with calibration before, everything must be great. It is, right up until you find out it isn’t from one of your customers, a regulatory agency, or when a product has to be recalled because of a measurement system error—one that could have been avoided if you had worked with your calibration provider to ensure they know what you need and you make sure that you receive it. Q

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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 Bar-

Harry C. Spinks, PMP, CMQ, CQE, CQA, is a metrology/quality engineer at Boston Scientific (Natick, MA). For more information, call (651) 269-3267, e-mail hcspinks@gmail. com or visit www.bostonscientific.com.

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October 2011 | QUALITY

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CASE STUDY

SOFTWARE REMOVES THE

HUMAN ERROR ELEMENT

Linear motion manufacturer saves time and reduces errors using software solution.

I

n 1983, a small company, Pacific Bearing Co., tackled what had become an industrial headache: failing linear ball bearings. With patented and innovative technology, the company has grown significantly since its founding, expanded its technology and now operates as PBC Linear, a manufacturer of hundreds of linear motion products from individual, out-of-the-box components and mechanical subassemblies to complete linear systems. The company’s linear motion components are sold assembled in preengineered systems, slides and stages to a vast array of industries, including the military, medical device, lab automation, packaging and industrial markets. All the company’s products are manufac-

tured at the company’s manufacturing facility in Roscoe, IL. With its wide variety of products, making sure products are designed efficiently and make their way through the product development process in a timely manner is essential to staying ahead of their competitors. The engineering team using SolidWorks mechanical computer-aided design (CAD) software creates 3-D models of the company’s products. After the models are approved and ready for production, 2-D drawings are generated from the 3-D models. The company’s team of engineering technicians then creates inspection sheets associated with each individual product for production. The inspection sheets are provided to production as Excel spreadsheets.

An added benefit to using InspectionXpert is that PBC Linear’s inspection sheets are now AS 9100-compliant, a benefit since the company is in the process of trying to obtain AS 9100 certification. Source: Extensible CAD

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Traditionally this process was done manually, with the engineering technicians entering dimensions from the drawings by hand in order to create the inspection sheets, a process referred to as chaotic by Mike McKee, one of the engineering technicians at PBC Linear. It also would require a lot of the technicians’ time to complete each one; a four or five-sheet drawing would require several pages of Excel files to do manually and would require anywhere from hours to up to a day to complete. The problem with this method was twofold: besides being time-consuming, it was inherently error-prone. “Sometimes the technicians might see the dimension, but type in the wrong dimension on the inspection sheet and not catch it until things were down the line,” says McKee. “The chance of human error is always there and sometimes these errors wouldn’t get caught until it reached the production floor.” McKee knew there had to be a better method, a way to “take the human error element out of the equation.” In 2007, he began researching possible automated solutions and came across Inspection-Xpert by Extensible CAD (Apex, NC). The startup had just begun selling a solution that appeared to do exactly what McKee needed—automated ballooning and creation of inspec-

InspectionXpert pulls information or dimensions directly from the source drawings or models, and then populates the Excel spreadsheet in minutes, a task that previously required hours of manual work. Source: Extensible CAD

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BENEFITS

dimensions, with Inspection drawings from CAD » Before it took a technitionXpert, at the most it drawings and models. cian a day to create an would take us 5 minutes McKee worked closely inspection sheet, but with to create an inspection with Extensible CAD InspectionXpert it now sheet,” says McKee. President Jeff Cope to see takes 5 minutes. “Without the software, it if InspectionXpert would » The InspectionXpert would have taken a techbe the solution they needsoftware also allows PBC nician a day to create that ed. McKee sent over some Linear to identify key same inspection sheet.” PBC Linear CAD files characteristics for parts, both design-critical and Besides removing the to Cope so the company manufacturing-critical. possibility of human could demonstrate how the error and speeding the software could help them » With InspectionXpert, PBC process, McKee says, “It save time and reduce the Linear’s inspection sheets makes us considerably chance of error when genare now AS 9100-compliant. more productive because erating inspection sheets. that’s primarily what we do daily, creThe demo showed how InspectionXpert ate drawings and inspection sheets. pulls information or dimensions directly The Inspection-Xpert software also from the source drawings or models, and allows us to identify critical (key) charthen populates the Excel spreadsheet in acteristics for our parts, both designminutes, a task that would have required critical and manufacturing-critical.” hours of manual work. The software outputs inspection McKee presented the demonstration sheets in the form of Excel spreadsheets, to upper management and his team tailored specifically for PBC Linear. The of four engineering technicians, all of inspection sheet is then attached elecwhich were very impressed and immetronically to the drawing and stored in diately purchased four seats of the the company’s product data management software. “Even on a six- or seven-sheet (PDM) system, so it follows the drawing drawing, with a couple of hundred

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through the entire workflow. Down the line, when someone goes into the PDM system to search for a particular drawing, they can also find and print out the associated inspection sheet as well. McKee says Cope and his team at Extensible CAD Technologies worked very closely with his team at PBC Linear, listening to their needs and adding functionality to the InspectionXpert software to fulfill those needs. “We were one of their first customers, so we were able to have a lot of input as far as different functionality. When we ask if it could do something, [Cope] would add it.” An added benefit was the fact that the company’s inspection sheets are now AS 9100-compliant, a huge benefit since the company is in the process of trying to obtain AS 9100 certification. “We found out that what we’re doing with these inspection sheets is actually 100% AScompliant now so we’re on our way to doing that now,” says McKee. Extensible CAD www.extensiblecad.com (800) 379-0322

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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

PAGE

CASE STUDY TITLE

Bal-Tec Division, Micro Surface Engr. Inc.

62

BALL BAR - DUMBELL

Carl Zeiss Industrial Metrology

63

CMM Learns New Tricks by Moving to CALYPSO Software

Comtorgage Corp

59

Internal Groove Measurement on Aluminum Beverage Cans

Cybermetrics Corp

61

Bosch Uses GAGEtrak to Ensure Accurate, Reliable Measurements of Their Gasoline Systems Products

DeFelsko Corp

60

Customer Success Story - DeFelsko

Gradient Lens Corp.

64

Borescope Assure the Quality of Mission Critical Aviation Parts

Heidenhain Corp.

63

Did you know…

Hexagon Metrology Inc.

59

Large Gear Measurement Comes to BIMAQ

Hommel- Etamic America

64

Optical shaft inspection is a H-O-G

Magnescale

60

Modern telescopes have become increasingly precise and are manufactured to operate at the highest tolerances

Mark 10 Corporation

61

Case Study: Candle Wick Tensile Testing

Micro-Vu

65

Multi-Sensor Machine Replaces CMM

Mitutoyo America Corp

62

Surface roughness measurement of tube Ids critical to volume producer of needles

Optical Gaging Products

66

Automated Measuring Systems Speed Production and Reduce Costs

Origin Technologies Corp.

66

New LaserGauge Sensor Automatically Corrects for Misalignment in Edge Break Measurements

Renishaw

65

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

Shimadzu Scientific Instrument

58

Video Extensometer Enables More Accurate, Efficient Measurements

Starrett Co., The L.S.

58

Tegra Medical Looks To The Future With Vision

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October 2011 | QUALITY

57

2011 CASE STUDIES

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Tegra Medical Looks To The Future With Vision For Tegra Medical of Dartmouth MA, quality is central to everything. Recently they upgraded their vision inspection capabilities by acquiring an automated Starrett Galileo AV300 Multi-Sensor System and a Galileo EZ200 Manual Vision system. The new systems replace or augment their older microscopes, comparators and vision systems with equipment that is more accurate, repeatable and easier to program and use. Programming of the AV300 system is fast and easy because all the needed tools are closeby on the desktop. In just a few hours the user can write a program to set up a large mold validation study involving the measurement of several critical features on large numbers of parts. It takes Tegra about a day to measure the parts, collect the data into an Excel spreadsheet and complete the study. This reduces the mold validation process by days and improves accuracy. Tegra Medical's AV300 system 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. This substantially reduces the need for cross sectioning, a very delicate and labor intensive pro-

cedure that adds hours to the measurement process. With these new Starret non-contact systems, the Dartmouth facility has very accurate video and multi-sensor measurement tools that increase throughput, meet today's needs and adapt to future requirements as the company customizes and fine-tunes manufacturing processes to satisfy its exacting customers. # # # About The L.S. Starrett Company Founded in 1880, The L.S. Starrett Company manufactures and markets a broad range of products including precision measurement tools, metrology equipment, band saw blades, power tool accessories, jobsite tools, granite surface plates and custom–engineered measurement solutions. Long known as “the world’s greatest toolmaker,” Starrett continues to set the standard of excellence through practical innovation, exceptional quality and unmatched precision. New Vision For The Future: Senior Process Quality Engineer, Maurice Leger at Tegra Medical’s Dartmouth, MA facility programs the company’s new Starrett Auto AV300 Multi-Sensor System.

For more information please contact The L.S. Starrett Company at 978-249-3551 or visit www.starrett.com.

Video Extensometer Enables More Accurate, Efficient Measurements files of a specified point (e.g. a break point) can be created from the recorded video sequence, and the images can be easily inserted into test reports for printing. TRViewX operates easily with TRAPEZIUMX software. Users simply select testing conditions to automatically set the measurement mode. The software synchronizes to the beginning and end of testing, and makes it possible to measure the actual gauge length when testing starts. By incorporating these and other functions, this system provides significantly more accurate measurements. And with the ability to Displacement is an important value in the context of universal testing machines, specifically for tensile tests that measure the strength

simultaneously measure elongation and width, it enables more effi cient testing and analysis.

of materials. Extensometers are used to perform high-accuracy displacement measurements. Offering precision, high-accuracy measurements, the TRViewX enables non-contact measurements of elongation and width utilizing a video camera, and is applicable for testing a variety of materials, including metals, plastics, rubbers and films.

58

Shimadzu Scientific Instruments

This machine can measure not only the elongation of a specimen

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QUALITY | October 2011

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Large Gear Measurement Comes to BIMAQ ment uncertainty of 1.3 +L/400 μm in the whole measurement volume of over 4 cubic meters, the Leitz PMM-F is one of the most accurate measuring machines of its class on the market," said Sebastian Haury, product manager for Leitz. The measurement range is 3000 x 2000 x 700 millimeters and a 20 ton granite block ensures structural strength. The Leitz PMM-F 30.20.7 was part of a turn-key solution, is equipped with QUINDOS 7 software, and can capture up to 750 points per second. Although the university owns a Leitz Reference Machine for other measurement applications, the new equipment was procured through an EU-wide tender. "Only one manufacturer was able to meet our high The Bremen Institute for Metrology, Automation and Quality Science

requirements," said BIMAQ Head, Prof. Dr. Ing. Gert Goch. "Thanks

(BIMAQ) at the University of Bremen opened the Laboratory for Large

to its high accuracy and especially its size, the Leitz coordinate mea-

Gear Measurement on August 5, 2011. Researchers can now investi-

suring machine from Hexagon Metrology got the nod for this project”.

gate the interrelationships between design, manufacture, quality and functional characteristics of large gears and their effects on wear,

For more information on this and other Leitz solutions,

service life, types of defects and noise. The goal is to establish the

contact us at 800-274-9433 or www.HexMet.us/qm1011.

laboratory as a certified testing authority for large gears, specifically those in wind turbines. Within the new facility is the Leitz PMM-F 30.20.7, a coordinate measuring machine (CMM) by Hexagon Metrology. "With a measure-

Internal Groove Measurement on Aluminum Beverage Cans ground blades. The three equally spaced blades retract into a housing, which pilots through the entry bore, and centralizes the gage. A depth stop is used to assist in locating the blades into the groove. After insertion of the gage into the part, the blades extend to contact the internal groove surface. Measurement results are monitored and collected via a Digital Indicator and computer interface. The easy to use Comtorgage has eliminated the guesswork found with go / no-go systems previously in place, and has reduced the number of rejected parts. Success of the Comtorgage “Can” gage has led to its use by other manufacturers of beverage containers both nationally and internationally. Quick and accurate verification of aluminum can dimensions insure Millions of aluminum beverage cans are filled each day with our favorite fruit juice, soda, and of course, beer. This process depends on

that the filling lines will move quickly and accurately to assure your favorite beverage is always available.

uniform characteristics of the can itself, as it is moved at hyper speed through the filling, sealing, and packaging process. A major American brewer (and manufacturer of beverage cans), asked Comtorgage to develop a gage to measure the rounded bottom groove on the underside of the can. This groove, which is crucial to locate and transport the cans, was difficult and time consuming to inspect. To accomplish this task, Comtorgage designed a special gage using its proven “retractable blade” design, utilizing three form

www.qualitymag.com

COMTORGAGE CORPORATION 58 NS Industrial Drive, PO Box 1217 Slatersville, RI 02876-0896 401-765-0900 www.comtorgage.com [email protected]

October 2011 | QUALITY

59

2011 CASE STUDIES

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Modern telescopes have become increasingly precise and are manufactured to operate at the highest tolerances. system that could offer high accuracy and high resolution dynamic measurement with a high speed interface. According to LCOGT's Mechanical Engineer Vincent Posner, “We use the Magnescale gauges to accurately measure the position of the primary mirror in our one meter telescopes”. Magnescale’s DK series digital gauges and MG41 Ethernet interface proved to be a perfect fit for their application. Accepting up to 100 digital gauges and offering 100Mbs Fast Ethernet, Magnescale’s MG41 interface has become the solution for multi-gauge applications requiring high speed data output. Similarly, Source: Matthew Christopher Miller the DK series of digital gauges with up to 0.1μm resolution, measuring A privately funded organization, Las Cumbres Observatory Global ranges from 2mm to 205mm, and up to 1μm accuracy, have become Telescope Network (LCOGT), is building a global network of telethe digital gauge of choice for even the most demanding of applications. scopes for scientific research and research-based education. To meet their highly precise operating tolerances, this private operating foundation turned to Magnescale’s line of high performance digital gauges and new Ethernet interface for communications. LCOGT required a

Customer Success Story – DeFelsko universal gage body that accepts all PosiTector DPM, SPG and 6000 probes- easily converting from a coating thickness gage to a dew point meter or surface profile gage. The universal solution offers the ability to share not only the gage body but also common software and cloud-based memory storage. Since all probes manufactured since 2007 are compatible with the new universal body, the customer was able to keep many of their existing probes to take advantage of the new PosiTector features. The universal PosiTector solution has many advantages including the ability to use different probe types on a single gage body saving money and time. The new PosiTector series has internal memory and Recently, a shipyard wanted a solution for measuring 3 important fac-

includes a USB port for fast, simple connection to a PC. Bluetooth

tors critical for the long term performance of coatings on steel struc-

options are available to support wireless communication.

tures – environmental conditions, surface profile of the blasted steel

60

and coating thickness. Ideally, the 3 solutions would share common

DeFelsko Corporation

software to satisfy their paperless QA requirements. As a longtime

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customer, they were familiar with DeFelsko’s PosiTector 6000 coat-

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ing thickness gage for metal substrates but now require additional

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QUALITY | October 2011

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Case Study: Candle Wick Tensile Testing Determining the crimp strength of a candle wick with metal clip base Wicks have been an essential component of can-

ESM301 motorized test stand with digital force

dles for centuries, providing light, enjoyment, and

gauge, wire terminal grip to secure the clip, and dual

other benefi ts in local restaurants, spas, houses

roller grip to secure the free end of the wick. The wire

of worship, and homes. The common expectation

terminal grip is attached to the force gauge, pulling

by candle manufacturers is that their candles’

upwards on the clip. After the wick and clip have

ability to burn evenly will result in a satisfactory

been dislodged from each other, the test stand’s

customer experience.

crosshead reaches a limit switch and returns auto-

To ensure the candle burns evenly, the wick

matically at high speed to the home position. The

must be centered and straight throughout the

force gauge transmits the force data to a PC for fur-

entire profile of the candle, whether it is freestand-

ther analysis in Mark-10’s MESUR™gauge software.

ing or positioned in a jar or votive. Many candle

Results are compared to a reference force range,

designs feature a wick with metal clip crimped to

allowing for quick identification of failures.

one end. This clip stabilizes the wick during the

The Mark-10 system was successfully imple-

candle manufacturing process. During produc-

mented and the manufacturer reports they are

tion, tension is applied to the free end of the wick during wax solidification to orient it axially. Sometimes, however, this tension is sufficient to separate the wick from the clip, resulting in manufacturing failures. One manufacturer of candles approached Mark-10 with a challenge

very satisfied by the improvement in throughput The force required to separate the candle wick from the metal clip is measured and used to proactively identify product failures, thereby reducing rework and recalls.

and consistency, to the benefit of their customers.

By Eric Johnson, Sales & Marketing Associate [email protected]

to improve their production process to minimize

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Mark-10 proposed a testing system to measure the force required

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to separate the wick from the clip. The system consisted of a model

Bosch Uses GAGEtrak® to Ensure Accurate, Reliable Measurements of Their Gasoline Systems Products. The Bosch Group is a leading global

Prior to GAGEtrak, the com-

supplier of technology and services in

pany used filing cabinets and

the areas of automotive and industrial

index cards to track calibrations.

technology, consumer goods and building technology. The Automotive

With

Technology division is Bosch’s largest business sector in North

tion tracking process at Robert

America employing approximately 12,200 associates at approxi-

Bosch became almost paperless.

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"GAGEtrak streamlined our recall

While there are 29 Bosch US and international facilities that have

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the

Anderson, SC location of Robert

GAGEtrak,

the

calibra-

process," says Ben Thomas, Bosch's principal GAGEtrak user. As a leading global supplier of automotive and industrial technology, Bosch is serious about quality and performance and chooses GAGEtrak to help ensure measurement accuracy and reliability.

Bosch is responsible for manag-

GAGEtrak is used at thousands of facilities worldwide to improve

ing 4,500 gages and conducting

measurement quality, assure compliance and increase efficiency.

4,000 calibrations each year to ensure accurate and reliable mea-

Contact CyberMetrics today to learn how GAGEtrak will do the same

surements of their gasoline systems products.

for your company.

Bosch chooses GAGEtrak Calibration Management Software to track their metrology assets, schedule their calibrations and maintain a system that is compliant with their corporate quality requirements and standards.

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October 2011 | QUALITY

61

2011 CASE STUDIES

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Surface roughness measurement of tube IDs critical to volume producer of needles

(Top) Detail of stainless steel micro tube bevel-cut to produce needle point. (Bottom) Finished needle. Image courtesy K-Tube Corp.

Stylus of Mitutoyo Surftest SJ-400 surface roughness tester is shown traversing ID of sectioned K-Tube micro tube needle stock. Image courtesy K-Tube Corp.

Mitutoyo Surftest SJ-400 with display/printer unit shown at top. Image courtesy Mitutoyo America Corp.

Stainless steel micro tubing – typically ranging in diameter from approximately 0.2” to 0.004” sometimes even smaller – is found in a wide variety of manufacturing applications including: medical, aerospace, energy, automotive and myriad other industries for fluid transport, dispensing, and mechanical structure. A sub-category of stainless steel micro tubing, medical/dental/hypodermic needle tubing, as the name implies, is small diameter needle stock which is hard drawn, cut and then ground to points to make hypodermic needles. With ever-tightening tolerances demanded by all parties to medical manufacturing processes, needle ID surface roughness is now commonly specified. K-Tube Corporation of Poway, California, (www.k-tube.com), the largest independent manufacturer of stainless steel micro tube in the United States, was an early adopter of measuring needle bore ID surface roughness – about 15 years ago it began engaging outside labs to make the measurements. But as interest in specifying ID roughness values continued to grow among K-Tube’s customers, (some of whom started to ask for Ra, Rq, and Rz parameters*) the company decided to attain an in-house, ID roughness measurement capability. Therefore about five years ago, the company installed a Mitutoyo Surftest SJ-400 portable surface roughness tester capable of making as many as 36

kinds of roughness measurements satisfying the latest standards issued by ISO, DIN, ANSI, and JIS. The instrument provides a measuring resolution of 0.000125μ-m/0.005μ-in. and a traverse range of 800μ-m/0.032μ-in. Surface roughness is evaluated using Mitutoyo’s SURFPAK-SJ roughness analysis software program. K-Tube samples finished tube ID roughness on every production run down to 0.018” ID. To obtain measurements, samples generally 2” long are sectioned length-wise by grinding so that one-half the tube is removed leaving the other one-half undisturbed and accessible to the SJ-400 instrument’s measuring stylus. The roughness data becomes part of K-Tube’s customers’ order certification and quality records. * Roughness profile parameters: roughness average (Ra), root mean square roughness (Rq), roughness height (Rz). Roughness profiles are the finer scale surface variations that remain after form and waviness variations have been filtered out of the raw profile. Mitutoyo America Corporation 965 Corporate Blvd., Aurora, Illinois 60502 USA Phone: (630) 820-9666 Fax: (630) 820-2614 www.mitutoyo.com - Mark Izumi, Advertising & Promotions Manager, [email protected] K-Tube Corporation 13400 Kirkham Way, Poway, CA 92064 USA Phone: (800) 394-0058 Fax: (858) 513-9459 www.k-tube.com - Lori Tysdal, Quality Manager, [email protected]

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 323-582-7348 been serviced and certified by the machines manufacturer at a cost

62

QUALITY | October 2011

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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

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

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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

October 2011 | QUALITY

63

2011 CASE STUDIES

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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]

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-

64

QUALITY | October 2011

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ADVERTISEMENT

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

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

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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

October 2011 | QUALITY

65

2011 CASE STUDIES

ADVERTISEMENT

Automated Measuring Systems Speed Production and Reduce Costs As a solution, Tessy implemented ten SmartScope® video metrology systems from Optical Gaging Products (OGP®) to supplement their installed base of comparators and CMMs. As explained by Mark Towers, Director of Quality Assurance, “We use CMMs for many dimensional measurements, and SmartScope systems when parts are too flexible for touch probing, or when the parts are simply too small to probe.” Parts are mounted on custom fixtures and measured in batches on SmartScope systems. Automated measurement routines free the operator to perform other tasks. Injection molding is a continuous process with batches of parts being formed while others are measured. When the molding process drifts out of tolerance, many “bad” parts may be produced before the problem is detected. Tessy monitors its processes by sending all SmartScope measurement results to QC-Calc™ software for graphical statistical monitoring. QC-Calc presentation of SmartScope measurements allows Tessy engineers to adjust processes before out-of-tolerance parts are produced. Accurate, speedy SmartScope measurements allow Tessy to maintain quality with lower labor costs. Tessy Plastics (www.tessy.com, Elbridge NY) is a plastic injection molder that produces a mix of products for medical and consumer companies. Tessy initially relied on CMMs and optical comparators to measure molded parts to keep processes in spec. Not only was this slow, it was labor intensive. In addition, the industry trend was toward part miniaturization. Tessy needed to automate their measurement processes to speed things up, reduce labor costs, and to measure new parts too small to measure on a comparator.

Optical Gaging Products (OGP®) 850 Hudson Avenue | Rochester, NY 14621 585.544.0400 or 800.647.4243 | Fax 585.544.8092 [email protected] | www.ogpnet.com

New LaserGauge Sensor Automatically Corrects for Misalignment in Edge Break Measurements The edge breaks on corners and edges of critical jet engine parts (disks, vanes, blades, etc.) must be shaped to within established maximum and minimum tolerances for the parts to be flight-worthy. A leading aircraft manufacturer using existing laser-based measurement systems found that sensor misalignment contributed to unacceptable measurement errors, making the inspection data unusable. This misalignment was due to the complexity of the parts and limited accessibility to the regions to be inspected thereby making consistent sensor positioning difficult. A hand-held measurement sensor was needed that would automatically correct for sensor misalignment but remain small enough to access the hard-to-reach areas of the jet engine parts. The USB-based LaserGauge HS720 sensor was found to be an ideal solution to mitigate concerns over unreliable data. The HS720 is unique in both design and functionality to correct for this problem. Its small size and reduced footprint gave it access to highlyrestricted areas. In addition, by utilizing a unique double-laserstripe design, it gave both cross-sectional scanning capability and sensor orientation feedback. By using the second laser stripe, the roll/pitch/yaw of the sensor relative to the optimum measurement orientation is calculated and automatically corrected, yielding the actual edge-break cross-section normal to the surface. For edge breaks in the range from 0.010” to 0.030”, measurement repeatability is within 0.001” after correcting for pitch, roll or yaw up to 10 degrees. The variation due to misalignment of a hand-held inspection tool was eliminated.

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QUALITY | October 2011

Edge Break Measurements The measurement algorithm utilized two methods for quantification of the edge break features. The simplest inspection method checks against minimum and maximum radius tolerance bands to verify that the scanned points fall within the tolerance bands. A secondary set of measurements were required to detect the condition where the edge falls within the max and min tolerance bands but still creates a stress point on these critical structures. If the radius of the edge break doesn’t “blend” into the adjacent surfaces, another stress point is created. The following diagram illustrates the edge break measurements acquired with the HS720: With its small size, sensor orientation feedback and advanced edge break measurement algorithm, the HS720 provided the quality of measurements to overcome shortcomings of other methods. Other Applications With the added capability for measuring chamfers, angles and steps, the lightweight, LaserGauge HS720 sensor was proven to be a more accurate way to manually inspect edge breaks. LaserGauge® Origin Technologies Corporation www.origintech.com 256-461-1313

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QUAL IT  Y 

M

AGAZI NE

    



u e s s i e v i t a commemor   



CELEBRATES

50 YEARS

These companies were advertisers in the very first issue of Quality. We thank them for being there to launch the beginning of a fabulous 50 years! AA Gage Company Ames Company, BC Ames Precision Machine Works Biddle Company Branson Instruments, Inc. Brown & Sharpe Manufacturing Comtor Company Cooke, Troughton & Simms Inc. Cubic Corporation Deltronics, Inc. Detroit Tap and Tool Company DoAll Company Dorsey Gage Company duMont Corporation Elliott Service Company, Inc. Endevco Corporation Engis Equipment Company Ex-Cell-O Corporation

Darrell Dal Pozzo Publisher (847) 405-4044 [email protected]

Barbara Grim Associate Publisher (856) 358-4800 [email protected]

Fairchild Semiconductor Fairfield Development Lab, Inc. Federal Products Corporation Greenfield Tap & Die Company Heise, Bourdon Tube Company International Machine Tool Corporation Jones & Lamson Machine Krautkramer Ultrasonics, Inc. MB Electronics Magnaflux Corporataion Mahr Gage Company Micro-Vu Coporation Midwest Gage Laboratory Millipore Filter Corporation Missimers, Inc. Morse Company Newage Industries, Inc. Nikon, Inc.

Buck Bicek Midwest & Southwest (630) 971-0904 [email protected]

Optical Gaging Products, Inc. Picker X-Ray Corporation Pratt and Whitney Company Qualitrol Corporation Rex Gauge Company Scherr-Tumico, Inc. Shannon Luminous Materials Company Simpson Electric Company Singleton Company Size Control Company Slocomb Company Starrett Company Sunnen Service Corporation Superior Mfg. & Instrument Corporation United-Greenfield Corporation Van Keuren Company Webber Gage Division Starrett Wyle Laboratories

Bill DeYoe Central & Southeast (704) 822-6434 [email protected]

CALL FOR NOMINATIONS! PAST PLANT OF THE YEAR RECIPIENTS: 2011 Daimler Trucks North America, Cleveland Truck Manufacturing Plant 2010 Pelco Products Inc. 2009 Lockheed Martin, Large Plant Div. Personna American Safety Razor, Small Plant Div. 2008 Ford Motor Co.-Van Dyke Transmission Plant

“Quality” plants deserve special recognition.

2007 Freightliner

That’s why Quality Magazine is presenting its 2012 Quality Plant of the Year Award.

2006 Kenworth Truck Co., Large Plant Div.

The award is open to manufacturing plants in the United States. The plant must be involved in making and measuring, testing or inspecting discrete parts. We’re looking for plants that have applied world-class quality technology, equipment, services and techniques that result in reducing scrap, rework, warranty or manufacturing costs, improve productivity or cycle time, increase capacity or improve adherence to quality standards.

Accurate Gauge and Mfg. Inc., Small Plant Div.

The Quality Plant of the Year award recognizes both a small plant of 250 or fewer employees and a large plant of more than 250 employees for its outstanding achievements in quality. Anyone can nominate a plant—employees, suppliers and casual observers are welcome to make submissions. Deadline for nomination forms is November 1, 2011. All nomination forms MUST include a list of equipment, and brand, used in the manufacturing facility. Nominations without this list will be disqualified. The Quality Plant of the Year will be profiled in the March 2012 issue of Quality Magazine. The winning plants must be available for interviews and photographs in November/ December 2011. An official nomination form must be filled out and returned to Quality Magazine by the extended deadline of November 1, 2011. All nominations will be evaluated by a review board of quality and manufacturing experts. The winning plants will receive notification in November 2011.

Nomination forms are available online at: www.qualitymag.com

2011 Recipient Daimler Trucks North America

CALL FOR NOMINATIONS!

Through its individual awards program, Quality recognizes an individual who, during the course of his/her career, has made outstanding contributions to the quality profession. All candidates are reviewed and scored by a board of quality and manufacturing experts. The Quality Professional of the Year will be profiled in the April 2012 issue of Quality Magazine. The individual must be available for an interview and photographs in January 2012.

PAST PROFESSIONAL OF THE YEAR RECIPIENTS: 2011 Forrest Breyfogle 2010 D.H. Stamatis 2009 H. James Harrington 2008 Peter Sanderson 2007 Jim Smith 2006 Roderick Munro

The Quality Professional of the Year will be notified in December 2011.

Deadline for nomination forms is November 1, 2011. Submission forms can be found online at: www.qualitymag.com

2011 Recipient Forrest Breyfogle

QUALITY

PRODUCTS THE LATEST PRODUCTS TO HELP YOU IMPROVE YOUR MANUFACTURING PROCESS

DATA COLLECTORS LASER DISPLACEMENT SENSOR The SI-F1000 Series micro-head spectral-interference laser displacement sensor is designed to provide high-precision performance in a 2-millimeter diameter sensor head. This unit is designed to provide laboratory accuracy measurements inside the production process and even inside assembled products. Because the SI-F1000 is a low-power optical system using fiber optic detecting, high-precision measurements can be taken without introducing electromagnetic effects or additional head to the measurement system. KEYENCE | (888) 539-3623 | WWW.KEYENCE.COM/PRSI

SHOCK ACCELEROMETER The Endevco model 73 piezoresistive triaxial shock accelerometer is designed to provide highreliability measurements in three orthogonal directions within a footprint measuring less than 0.2 square inch (5.08 mm2). Units are available in ranges of 2,000, 6,000, 20,000 and 60,000 grams with frequency response capabilities down to DC (steady state), making them a choice for the support of long duration transient measurements.

The new Type 5630M Series of data collectors was developed to include all processes that a customer would need for long-term viewing. By assigning a unique part or serial number to each data file, the operator can quickly search, locate and view all historical process data. The part search screen, or dashboard, can be user-customized to display an image of the component, allowing for a clear visual representation of the process. The system offers a statistical process analysis module, which allows the operator to select a specific manufacturing application, along with an associated date range, to display various statistics, including mean values, standard deviations, Six-Sigma statistical measurements of Cp and Cpk, and others, within a single screen view. KISTLER (888) KISTLER

MEGGITT SENSING SYSTEMS | (949) 493-8181 | WWW.MEGGITTSENSINGSYSTEMS.COM

WWW.KISTLER.COM

SURFACE IMAGING AND ANALYSIS The standard ConfoMap ST package includes numerous analytical studies. Geometric studies calculate distances, angles, areas, volumes, and step heights on 2-D profiles and 3-D surfaces. Functional studies, including the bearing ratio curve and height distribution, facilitate the assessment of friction and wear on engineering surfaces. The roughness and waviness components of a surface are separated using the latest ISO 16610 advanced filtering techniques and 3-D surface texture parameters are calculated in accordance with ISO 25178 standard. DIGITAL SURF | +33 (0)38150 4800 | WWW.DIGITALSURF.FR

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QUALITY | October 2011

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Quality Magazine Classified Ads Policy

12/23/10 8:55 AM Classified ads are accepted at the discretion of the publisher, and are limited to:  Used/Refurbished Equipment  Aftermarket Accessories and Replacement Parts  Services, including laboratories  Employment  Black & White or 2-color ads

Carl Zeiss Industrial Metrology [email protected] (248) 867-3699 www.zeiss.com/ct-services

New equipment in a classified ad will be rejected unless the company has a contracted and approved display advertising program.

LISTEN TO THE LATEST INDUSTRY NEWS WITH Q-CAST Q-Cast Podcasts feature the latest news and information for quality test and inspection professionals—all in a bi-monthly newscast format that you can download to your computer or listen to directly from Quality Magazine’s Web site.

Visit www.qualitymag.com 0909-house-qcast-Orange-rast.indd 5 0511-QLTgetconnected.indd 6

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11/10/09 10:05:36 AM

4/6/11 10:28 AM

October 2011 | QUALITY

71

ADVERTISING INDEX

155 N. Pfingsten Rd., Suite 205 Deerfield, IL 60015

GROUP PUBLISHER

Darrell Dal Pozzo (847) 405-4044 [email protected]

ADVERTISER

PAGE

WEB SITE

Accelper Consulting

53

www.accelper.com

Automated Precision Inc.

IBC

www.apisensor.com

Bal-Tec Division, Micro Surface Engr. Inc.

51

www.precisionballs.com

Comtorgage Corp.

47

www.comtorgage.com

CyberMetrics Corp.

BC

www.cybermetrics.com

DeFelsko Corp.

50

www.defelsko.com

Dorsey Metrology International

39

www.dorseymetrology.com

G & R Technology Inc.

18

www.grhardnesstester.com

Gradient Lens Corp.

37

www.gradientlens.com

Heidenhain Corp.

31

www.heidenhain.us

Hexagon Metrology Inc.

23

www.hexagonmetrology.us

5

www.hommel-etamic.com

Imada

18

www.imada.com

Kotem

27

www.kotem.com/sp

Ledford Gage Lab

12

www.ledfordgage.com

Magnescale

13

www.mgscale.com

1, 16, 19, 53

www.mahr.com

9

www.mark-10.com

Micro-Vu

49

www.microvu.com

MicroRidge Systems Inc.

14

www.microridge.com

Mitutoyo America Corp.

IFC

www.mitutoyo.com

O.C. White Co.

30

www.ocwhite.com

Optical Gaging Products

17

www.ogpnet.com

Origin Technologies Corp.

27

www.origintech.com

PQ Systems

37

www.pqsystems.com

Renishaw

15

www.renishaw.com

3, 25

www.starrett.com

S-T Industries Inc.

11

www.stindustries.com

Society of Manufacturing Engineers

43

www.fabtechexpo.com

Wenzel America

12

www.wenzelamerica.com

Western Gage Corp.

16

www.westerngage.com

REGIONAL MARKETING NEW ENGLAND AND MID-ATLANTIC

Barbara Grim 1288 Centerton Rd. Pittsgrove, NJ 08318 Phone: (856) 358-4800 FAX: (856) 358-0900 [email protected] CENTRAL AND SOUTHEAST

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

Buck Bicek 5820 Middaugh Ave. Downers Grove, IL 60516 Phone: (630) 971-0904 FAX: (248) 502-1086 [email protected]

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].

72

QUALITY | October 2011

Hommel-Etamic

Mahr Federal Corp. Mark-10 Corp.

Starrett Co., The L. S.

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

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A Special Section to

Magazine

October 2011 www.ndtmag.com

nondestructive testing including materials test

Advances in RVI p. 16

NDT

The Evolution of Hardness Testing p. 10NDT But is it Bonded? p. 23NDT

THE STANDARD IN PHASED ARRAY, REDEFINED This second generation OmniScan flaw detector increases testing efficiencies, ensuring superior manual and advanced AUT application performance with faster setups, test cycles, and reporting, in addition to universal compatibility with all phased array modules. The OmniScan MX2 offers a high acquisition rate and new powerful software features—in a portable, modular instrument—to efficiently perform manual and automated inspections.

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October 2011

DEPARTMENTS Source: TUV Rheinland Industrial Solutions

4NDT

Editor’s Note It’s the End of the World… And I Feel Fine.

HARDNESS TESTING

6NDT

10NDT The Evolution of Hardness Testing

26NDT Back to Basics: Videoscopes

Hardness testing methods have been in use in various formats for more than two centuries and have provided valuable and pertinent material information throughout this time, from the industrial revolution to world wars to space exploration and, most recently, the electronics and information age.

REMOTE VISUAL INSPECTION

16NDT Advances in RVI While there are other instruments and methods than can sometimes help determine the condition of wearing components, nothing is quite as useful as a visual inspection.

Industry News

IBCNDT Products IBCNDT Advertising Index

IN THE NEXT ISSUE NDT Training Phased Array

NDT LAB SERVICES

NDT Rental

20NDT Sorting and Containment Services Using Radiography

NDT Education

A lab services team can travel to a location to provide on-site inspection, sorting and containment services to minimize possible production disruptions.

NDT eXtra What Lies Beneath?

BOND TESTERS

23NDT But is it Bonded? Many products have internal bonded interfaces between materials and the problem for assemblers is determining whether the materials are truly bonded over an adequate area.

A small blister on a hull can be just that, or it can be hiding something nastier, like impact damage to the core behind the skin. But how do you find out if a repair’s needed without actually sawing a chunk out? United Kingdom leisure marine business periodical Boating Business examines the answer.

ABOUT THE COVER Pictured is the articulating tip of a videoscope that contains a microcamera, LEDs and “bending section.” Source: RF System Lab

Source: RF System Lab 2 NDT ● OCTOBER 2011

NDT SPECIAL SECTION

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 Compact, lightweight lamp with two ultra-high-intensity UV-A LEDs for inspection, plus a three-LED white light assembly for general illumination

 Nominal steady-state UV-A intensity of 4,500 μW/cm² at 15 inches (38 cm)  30,000-hour LED service life  Adjustable strap allows lamp to be worn on a hard hat or directly on the head for hands-free operation!

 Unique lamp mount/sprayer permits lamp and spray can to be mounted together for single-handed fluorescent yoke inspection

 Built-in fan keeps LEDs cool to maintain optimum light output  Splash guard with integral particulate filter protects UV lenses and cooling fan from damage

 Also includes lanyard, two replacement splash guards with integral particu-

 Features four broad-beam lamp heads, each with three ultra-high-intensity UV-A LEDs for inspection, plus one white light LED for general illumination Nominal steady-state UV-A intensity of 9,000 μW/cm2 at 15 inches (38 cm) 30,000-hour LED service life Built-in fans keep LEDs cool to maintain optimum light output Fully customizable! Move, adjust and add lamp heads onto track section according to your specific inspection requirements (additional lamp heads sold separately).  Optional remote control with three-position rocker switch provides added convenience and versatility  UV-absorbing spectacles included

   

late filters, three spare batteries, battery charging cradle with AC and DC cord sets, UV-absorbing spectacles and soft carrying case

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It’s the End of the World…And I Feel Fine I have to admit, when I was making plans to attend the annual NCSL conference in Washington, D.C., I was not expecting an earth-shaking experience, but that is exactly what I got. On August 23, a magnitude 5.9 earthquake hit the east coast of the United States and when it was all said and done it wasn’t only the host of equipment on display at the Gaylord National Convention Center that needed recalibration, but also my equilibrium. Darryl Seland Editor in Chief [email protected]

T

The go good news is that little damage was do few were injured and I left the condone, ference with some valuable information fer ferenc and the an th beginnings of new relationships wi within the industry. However, as I arrived home, the news was of a very large hurho home ricane moving up the Atlantic Ocean. CNN immediately turned its attention to 24-hour coverage of Hurricane Irene, lines began to form at the local gas stations and supermarket shelves became bereft of milk and bread. Said supermarkets also

"Imagine the greater confidence and success of a firefighter when his tank will not fail on the 30th floor of a building fire."

prominently displayed pallets of bottled water at its entrances and throughout the store. I don’t want to make light of the situation as I have personally experienced few hurricanes and only one earthquake, but whether it is advantage-taking marketing on the part of the markets or an attempt to grab ratings by CNN, the above 4 NDT ● OCTOBER 2011

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are all fairly predictable reactions to a potential eminent crisis. And this is a good thing. Predictability means reliability and reliability, particularly when talking about natural disasters, can save lives. And nondestructive technology plays an important role in this reliability. Imagine the greater confidence and success of a firefighter when his tank will not fail on the 30th floor of a building fire, the ability of an EMT to resuscitate a heartattack victim with a properly functioning defibrillator or the ability of a bridge to withstand tremendous storm surge allowing people to escape a life-threatening storm, all because the tank, defibrillator and bridge were tested for potential defects using non-destructive technology. Find out more about the role nondestructive technology can play in this month’s NDT Magazine features, including “Is It Bonded?” by Tom Adams. See what’s new in remote visual inspection in Sean O’Connor’s “Advances in RVI” and read about some of what lab service providers can offer to a manufacturing operation in Mike Forbes article, “Sorting and Containment Services Using Radiography.” As always, enjoy and thanks for reading! www.ndtmag.com

Today’s commercial and military aircraft fly much faster, higher and farther than their predecessors did in 1941, the year X-Ray Industries was founded. What hasn’t changed, though, is the leadership X-Ray Industries’ displayed then and continues to demonstrate today. We remain committed to inspecting your products for integrity and reliability quickly and cost-effectively using state-of-the-art NDT technologies. We also recently expanded our services to include surface engineering technologies so our customers can enjoy

the convenience and efficiency of a single source for all their conversion coating, plating and painting needs. To find out more about X-Ray Industries and its affiliated companies, visit us on the web at www.xrayindustries.com or call us at 800-962-1788.

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TVA Supports Degree Program at Chattanooga State CHATANOOGA, TN (TheChattanoogan.com)—The Tennessee Valley Authority, in cooperation with Chattanooga State Community College and the American Society of Mechanical Engineers, has developed an associate degree program in nondestructive testing that will graduate students and provide them the opportunity for national certification making them ready to perform inspections and testing for multiple industries including TVA’s nuclear power plants. “The American Society of Mechanical Engineers has safety and inspection codes that must be followed telling us what materials to use when building specific equipment, how to perform the welding necessary and then how to inspect this equipment to keep it in good work-

6 NDT ● OCTOBER 2011

ing order,” said Mike Turnbow, general manager of TVA’s Inspection and Testing Services. “What TVA needed were those skilled people to perform the inspections and certify that our equipment was working as intended,” added Turnbow. Turnbow, other TVA volunteers and local inspection service providers helped write the new course at the same time they taught the first students at the Chattanooga State campus after workinghours. “Our first two students graduated this year with their associate degree and TVA now has five interns learning the work they would do in our plants as they move toward graduation,” said Turnbow. “We are excited to help move this field forward by offering students the capabilities needed at the same time they get

NDT SPECIAL SECTION

a chance for high paying jobs.” TVA began working on this program with Chattanooga State three years ago when TVA committed to ASME assistance in helping them build a national examination and certification program. The program certifies that these and other graduates are capable of inspecting essential equipment in industries and power plants nationwide. For more information, visit www.tva. gov.

SGS Acquires Acumax Ltd. GENEVA, SWITZERLAND— SGS is pleased to announce the acquisition of Acumax Ltd (Gauteng, South Africa). Acumax specializes in nondestructive

www.ndtmag.com

testing (NDT), rope access services and ultrasonic inspections. Acumax serves the industrial, oil and gas and offshore industry in South Africa and the coast of Africa. Founded in 2008 and privately owned, Acumax employs 12 staff and revenues for the prior year were in excess of ZAR 8.1 million, or roughly $1.1 million. “SGS is excited by the prospect of building on the foundations of the Acumax business and investing and expanding our Industrial Services portfolio in the Southern African region”, says Chris Kirk, CEO of SGS. The SGS Group is a global inspection, verification, testing and certification company. Founded in 1878, SGS has than 67,000 employees. For more information, visit www. sgs.com.

include certification of the process for each jet-engine OEM and its suppliers, further equipment-manufacturer evaluations and selection, and final approvals for testing procedures related to data capture, manipulation, analysis and reporting. “It is possible these issues

can be resolved during the first half of 2012,” says Fletcher. “In any event, by that time West Penn will be in a position to conduct a high rate of titanium billet inspections.” For more information, visit www.westpenntesting.com

West Penn Accelerates TestProcess Development in Wake of FAA Approval of Phased Array Ultrasonic Testing NEW KENSINGTON, PA--West Penn Testing Group, a provider of nondestructive testing and material testing services, reports completion of FAA approvals for phased array ultrasonic testing (PAUT). According to Albert Fletcher, director of sales of West Penn Testing, “The titanium-billet-phased-array group, made up of jet-engine OEMs, titanium-billet manufacturers and aerospace forgers, has passed a crucial milestone with the approval last month of PAUT. After a three-year effort, the aerospace industry now has an alternative to multi-zone ultrasonic testing.” Fletcher says that as a result of the FAA approval, West Penn has sped up its program to develop test protocols that meet the requirements of individual OEM customers. “We have the trained people in place and the schedule to install the additional equipment well underway. Now, as we begin to receive the detailed testing requirements from various jet-engine OEMs, we can adapt our process to satisfy the demands of specific customers.” West Penn reports that a number of tasks must be completed before high volumes of titanium billets can be run through the PAUT process. These tasks www.ndtmag.com

METROTOM. We call it a CMM with an x-ray sensor. Metrotomography, the fusion of metrology and tomography, lets you non-destructively validate difficult interior and exterior GD&T dimensions. Both the METROTOM 800 and 1500 are traceable, calibrated gages. These systems are ideally suited in R&D, mold setup and ongoing quality control. They can also be used for assembly verification, void analysis, wall thickness analysis and reverse engineering. www.zeiss.com/METROTOM

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NDT Market to See Continued Growth SAN ANTONIO, TX—Nondestructive test (NDT) inspection service has been one of the few markets that performed impressively during the global economic downturn, according to market research firm Frost & Sullivan. It witnessed modest growth in 2009 and rebounded with an unexpectedly improved performance in 2010. North America is the main contributor to revenues, due to high government safety regulations stipulating that inspection be carried out regularly, even during the downturn. Europe is the second largest contributor to revenues in this market. The development of wind farms across Western Europe, particularly in countries such as Spain and Germany, is creating demand for NDT inspection services. However, the growth of NDT inspection services in this region is expected to be slower when compared with other regions.

8 NDT ● OCTOBER 2011

Frost & Sullivan says the worldwide NDT market earned revenues of $3.05 billion in 2010 and estimates this to reach $5.59 billion in 2017. Even though industries were hit severely during the economic downturn, the global NDT inspection services market revenues registered a growth of 4.7% in 2009. However, with the U.S. economy still recovering from the effects of financial downturn and the European economy being troubled by a sovereign debt crisis, the primary regions being outlined for growth in the global market are Asia Pacific and Latin America. “The rapid rate of infrastructure development in emerging economies such as India, China, and Brazil is driving the demand for NDT inspection,” notes Frost & Sullivan Research Associate Nikhil Jain. “In Japan, the accident at Fukushima nuclear reactor is expected to trigger widespread increase in safety regulations for nuclear power plants, besides driving short-term precaution-

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ary inspection in existing nuclear plants worldwide.” Meanwhile, in Latin America, Brazil has been the vanguard of the market recovery. The Brazilian economy is the largest in Latin America, with oil and gas, power generation, aerospace and automotive sectors being the main revenue generators. In this region, the majority of the revenues came from oil and gas end use segment, which perform compliance-based maintenance inspection. The power generation segment, especially wind energy and nuclear power, also provides expansion opportunities to NDT inspection service providers. The awareness of the need for NDT inspection in these regions is low; however, industries are beginning to understand the importance of protecting their assets against catastrophic failures. “Although most established participants provide high-quality inspection, less established and relatively smaller

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participants occasionally compromise on safety and quality,” says Nikhil. “This is especially witnessed in Asia Pacific, where the end-users are highly price conscious.” Price is a major hurdle for many NDT inspection service providers in Asia Pacific. The lack of government safety regulations has affected the effective implementation of NDT inspection in this region. End users are unconcerned about the reputation and quality of the inspection service provider, but they demand the most competitive price-performance ratio. With the number of pipeline explosions and infrastructure failures being witnessed around the world, authorities have intensified the scrutiny of inspection performed. Also, many industries that are reluctant to incur the exorbitant installation costs of new infrastructure are trying to extend the useful life of their existing assets. This has led to relative aging of these assets and periodic inspection is essential to guard against catastrophic failure. To tap this ever increasing demand for NDT inspection, the service providers need to increase their market presence and technicians employed. However, this offers a considerable challenge as there is a clear lack of qualified and skilled technicians in this industry. To overcome this challenge, NDT equipment manufacturers have dedicated their resources to simplify the operational complexity of the instrument used for inspection and increasing the speed of inspection. As a result, technicians have additional time to perform a thorough analysis of the data collected. For more information, contact Sarah Saatzer at [email protected] or (210) 477-8427, or visit www.frost. com.

NDT Specialists Plans to Build Wisconsin Facility OAK CREEK, WI (OakCreekPatch.Com) —NDT Specialists Inc. is planning to consolidate its operations and build a $1.5 million facility in Oak Creek, WI. The company performs inspection services on various parts for a wide range www.ndtmag.com

of industries and manufacturers (Caterpillar, for example). NDT, short for Non-Destructive Testing, has been in business since 1988 and has locations in West Allis and Milwaukee. Those would be combined under one roof at 7365 S. Howell Ave.

Owner Larry Schneider, an Oak Creek resident, said the family-owned NDT employs 26 people with an average wage of $20 per hour. The company has grown steadily over the past 20-plus years and expects to continue to expand in Oak Creek, Schneider said.

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OCTOBER 2011 ● 9 NDT

The Evolution of Hardness Testing Hardness testing has evolved quite dramatically from simple scratch-testing to motorized testers to today’s sophisticated, fully automated, computer-controlled systems. By Bill O’Neill Hardness H Ha a testing methods have been in use formats for more than two centuin n various var rries ri e aand have provided valuable and pertinent es material m ma ate tterr information throughout this time, from industrial revolution to world wars to space thee in exploration and, most recently, the electronics explor plor pl or and information age. During these years, hardness testing has evolved quite dramatically from simple scratch-testing to motorized testers to today’s sophisticated, fully automated, computercontrolled systems. From its early origins in scratch testing, circa 1722, the development of hardness testing instrumentation has been consistent with evolving technology and, in many ways, the refinements

Early hardness test block calibration laboratory’s used analog, deadweight Rockwell testers. Source: Wilson Hardness 10 NDT ● OCTOBER 2011

NDT SPECIAL SECTION

paralleled engineering accomplishments of the relevant era. Some of the first types of hardness tests originated on bars that varied in hardness from endto-end. The concentration at which the material being tested could form a scratch on the bar was a determining factor in the specimen’s hardness. These early, crude forms gave a relative and often comparative indication of material strength and were adequate for the time. More refined forms of scratch testing were introduced during the 1800s by a German mineralogist named Friedrich Mohs. In what eventually became known as the Mohs hardness test, the user would scratch an unknown sample with a material of known hardness. Later, this test was improved to a more standardized format and involved scratching material surfaces with a diamond and measuring the width of the resultant line. Mohs chose a diamond, of course, based on its property as the hardest known natural substance and the fact that a diamond can produce a scratch on virtually all other substances. This refined test utilizes a scale from 1-10, the higher the value, the harder the material. In some processes the Mohs method is still utilized today. Varying scratch-test forms continued to be introduced over the next 100 years or so, none really gaining a hold in materials testing the way the Mohs test did. The first transformation to a more systematic testing format came with the introduction of the indentation test. The earliest form was introduced in 1859 and was based on the force required to produce a 3.5 mm indent in the test material. The depth was measured with a vernier scale system and the total weight needed to reach the 3.5 mm was indicated as the hardness. The penetrator consisted of a truncated cone that tapered from 5 mm at the top to 1.25 mm at the point. This method was mostly effective with soft materials. www.ndtmag.com

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A Production Brinell system can perform fully automated, depth-of-penetration testing for 100% inspection of railroad wheels. Source: Wilson Hardness

The first widely accepted and standardized indentation hardness test was proposed by J. A. Brinell in 1900. His goal was to find 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 mm diameter ball at heavy loads of up to 3,000 kg. The resultant circular impression was, at the time, measured with a low-power manual eye microscope. The diameter of the impression was then

TECH TIPS ● The earliest indentation test was based on the force required to produce a 3.5 mm indent in the test material. ● The depth was measured with a vernier scale system and the total weight needed to reach the 3.5 mm was indicated as the hardness. ● The Brinell hardness test consists of indenting the metal surface with a 1 to 10 mm diameter ball at heavy loads of up to 3,000 kg. ● Hardness testing has rapidly evolved in technique, more so in the past 20 years than the previous 100. 12 NDT ● OCTOBER 2011

mathematically calculated to a 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. Today, the Brinell test remains common in testing aluminum and copper alloys (at lower forces) and steels and cast irons at the higher force ranges. The test method is particularly useful in certain material finishes as it is more tolerant of surface conditions due to the indenter size and heavy applied force. Brinell testers are often manufactured to accommodate large parts, such as engine castings and large-diameter piping. Today, in addition to the still widely used manual microscopes, automatic camera systems are capable of rapid and extremely accurate result generation. While the Brinell test proved to be an effective and productive means of material testing, and surely contributed to ushering in a new standardized era in hardness testing, it did have limitations. For one, the relatively large size of the indenter, along with the high test forces, made it inadequate for small precisiontype testing. The nature of the test also requires a second operation to measure the indent. In addition, the heavy force required by the test leaves an obvious and potentially damaging impression,

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so finished goods testing is not always practical. For these reasons, as well as the increasingly high demand for reliable and productive testing techniques that were the byproduct of the time—notably the industrial age and the record-breaking levels of machinery and component manufacturing in support of both World Wars—the hardness testing element of material analysis remained restless for change. The race was on to develop even more efficient methods. With that came the first acceptable alternative to the Brinell, the Vickers hardness test, which partially solved the problem by providing a more consistent, lighter load hardness test. Developed in the U.K. in 1924, the test used the same principle as the Brinell, that of a regulated impression, but utilized a pyramidshaped diamond rather than the Brinell ball indenter. The resultant impression or un-recovered area is measured using a high powered microscope in combination with filar measuring eyepieces. Later, in 1939, an alternative to the Vickers test—called the Knoop test— was introduced by 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. These test methods are widely used today in the analysis of small test areas, brittle materials, case hardened and steel components, coatings, wire and other precision parts but now often utilize much more advanced indentation and measuring techniques. Still, a desire and a drive towards even more efficient test methods remained and the answer became the Rockwell indentation test. The Rockwell method, originally introduced in a basic form in 1914, essentially revolutionized hardness testing, using displacement measurement and thereby producing a directreading result, eliminating the need for time-consuming secondary measuring operation. With full cycle-test-time requiring about 12 seconds, and in some cases as little as 3 seconds, the desired productivity and efficiency, along with accuracy, was finally realized. The methods patent application was approved in www.ndtmag.com

1919 and, in 1924, an improved design patent was granted. Simultaneously, commercial production of Rockwell testers was underway and it became the primary, preferred method for testing, enduring in that significance today. With the primary test methods, Brinell, Knoop, Vickers and Rockwell now defined and firmly established as useful and reliable material test techniques, it was left to technology to methodically and more dramatically improve on the instruments that performed the tests, as well as the processes to make these tests as efficient and accurate as possible. Notable in late the 20th century was the introduction of load cell force regulation in response to the need for improvements to the highly mechanical, traditional deadweight systems, which were very labor intensive to manufacture and required considerable maintenance to sustain accuracy and standards compliance. Closed-loop design is based on transducer technology

During the early 1990s, this technology was introduced first to Rockwell testers and later to Knoop, Vickers and Brinell systems. electronically measuring the force being applied during actuation of the indenter, usually by a servo motor, during every test and processing 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. During the early 1990s, this technology was introduced first to Rockwell testers and later to Knoop, Vickers and Brinell systems. Closed-loop quickly gained momentum as a means to achieve extremely accurate and repeatable hard-

ness test results. Today, the technology is a popular and widely used format. In recent years, significant improvements in hardness testing instrumentation, as well as computer hardware, electronics, imaging algorithms and software capabilities, have opened the door to newer, extremely precise and reliable testing processes that provide results more quickly than ever before. These components and techniques have proven to be beneficial in raising efficiency, speed and accuracy to levels previously not possible, minimizing or eliminating

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OCTOBER 2011 ● 13 NDT

many of the manual techniques used from the onset of the standardized testing period. One means of improving productivity while providing consistency to the process is through automatic indentation and impression reading utilizing image analysis. Over the past several years, and no doubt increasingly in the future, manual processes have and will continue to rapidly give way to automation in every aspect of the testing process. New, extremely efficient techniques in material preparation and handling, mount fixturing, stage movement, results interpretation, analysis and even reporting have been introduced. An important and productive technology being integrated into many hardness systems around the world is automatic stage traversing and image analysis of hardness impressions. Two of the more common hardness tests mentioned, Knoop and Vickers, have benefited greatly from these advancements. The nature of these test types typically dictates a lower force consistent with the material being tested, usually resulting in extremely small impressions that must be measured at the micron level. Traditional techniques, still practiced today, involve microscopes with objectives of varying resolution integral to the hardness tester, which are used to manually measure the impression through an eyepiece and are based on human interpretation. Predictably, this is time-consuming, inefficient and—in today’s fast paced, extreme environment—increasingly unacceptable. An automatic hardness system typically consists of a fully controllable tester, including an auto-rotating or 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. After initial setup with samples and an applicable traverse and parameter program, the system can be left alone to automatically create, measure and report on an almost unlimited number of indentation traverses. 14 NDT ● OCTOBER 2011

A closed-loop, control-design Rockwell tester. Source: Wilson Hardness

The technology driving image analysis continues to advance, considerably improving the indent measurement process from the earlier, more limited form that had inadequacies in measuring smaller indents and samples with lesser surface finishes. These high requirements in regards to surface preparation, along with process restrictions, meant previous systems were lacking in effectiveness as a complete solution. The capabilities of current and developing cameras, coupled with the processing capacity of today’s PCs and continually improving software packages, have significantly improved the accuracy, repeatability and dependability of automatic indentation reading. It is now possible to accurately and repeatedly read smaller-than-ever indents and locate and analyze indents on surfaces and material previously not possible, such as glass. In addition, new developments in

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microscope objectives and digital-zooming technology are allowing for wider magnification ranges than ever before. With a push to expand productivity even further, manufactures next introduced the ability to utilize larger-size, automatic traversing XY stages capable of holding two, four or even six samples at a time in an array of fixturing types. Pre-programmed and saved traverses are opened, samples are aligned in holders and with a single click the indentation, reading and reporting of a multitude of traverses on each sample is initiated. Autofocus mitigates any compromise of indent clarity due to small parallelism position variation. Newer software even allows different scales, forces and microscope objectives within and between traverses, creating new possibilities and combinations in multi-sample and casedepth analysis. This fully frees the operator from manually moving the sample from test to test for both the indentation and the measurement process and quickly provides an ROI and benefit that is readily evident and clearly increases the ability to evaluate a variety of materials. Automated testing also is increasingly beneficial for Rockwell hardness testing, particularly in repetitive pattern requirements such as Jominy testing, where a number of bars can be fully tested and reported, unmanned after one click of the mouse. The use of an automated stage and software integrated with a Rockwell tester capable of automatic actuation allows for multiple sample testing; in some cases, manufactures are automatically testing more than 15 parts on a stage with multiple indents on each part. As in Knoop and Vickers testing, Brinell testing, a labor intensive and manual process that requires constant human intervention, became a target for improvement and efficiency gains. With many processes requiring 100% inspection and productivity dependent on quick results, it is no surprise that a means to both accelerate the process and mitigate possible manually induced errors became a priority for the method. In reaction, the Production Brinell test was introduced, also in the late 20th century, as a unique method of automatically and accurately determining Brinell hardness in a production environment. Through www.ndtmag.com

the use of the Rockwell test principle of measuring depth of penetration to determine hardness, the Production Brinell test eliminates the costly and time-consuming procedures associated with conventional Brinell testing. In the process, the part is pre-clamped with sufficient pressure to prevent it from moving during the test process. Next, the test is performed applying a pre and full test force for a specified dwell time. Upon dwell completion, the part is unclamped. The test result is obtained by measuring the difference between the reference depth and the final depth after recovery has taken place. Production Brinell systems were soon integrated to production automation lines to perform quick and consistent production type Brinell testing. To meet the needs of testing that was required to adhere to the more common, optical Brinell standard, other means of productively performing optical Brinell measurements became available. As an alternative

to the hand-held manual optical measuring process, a hand-held digital camera that can accurately and efficiently measure the diameter of the impression automatically using image analysis techniques, was introduced at about the same time. As a result, it became relatively easy to measure Brinell indents through a camera. As the hand-held imaging system, which still required some manual intervention, was lacking in the often-desired production level, the process gave way to development of fully automatic, optical Brinell systems, introduced during the 1990s, which could provide adherence to ASTM E-10 while allowing for fully automated optical testing. The fully integrated automatic optical Brinell testing system can quickly and accurately perform the entire Brinell test process, including accurate indentation application and indent measurement through an image analysis system to autofocus on, identify and record indent size and hardness measurement.

Consistent with recent amazingly and exponentially evolving technology, hardness testing has rapidly evolved in technique, more so in the past 20 years than the previous 100. Limitations in regards to material geometry, surface finish, productivity, efficiency, data manipulation and reporting have been mitigated and are continually undergoing improvement. The result is increased ability and dependence on “letting the instrument do the work,” contributing to substantial increases in throughput and consistency, while freeing up the operator for other responsibilities. With a fully integrated system now available, the labor intensive, subjective and error-prone processes of the past are virtually eliminated and replaced with a significantly more accurate and productive process. NDT Bill O’Neill is Director, Business Development and Sales for Wilson Hardness. E-mail: [email protected]

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OCTOBER 2011 ● 15 NDT

Advancements

IN RVI

Remote visual inspection (RVI) technology can have a huge impact on maintenance and repair expenses and, most critically, downtime. By Sean O’Connor

F

rigid borescopes that relied upon mirrors and lenses, to fiberscopes that utilize highly flexible fiberoptic strands to transmit a remote image, to the current technology in which distally-mounted micro cameras are used to capture real-time, high-resolution images. Along the way, advancements in articulation mechanisms now allow a technician to accurately control exactly where the micro camera is pointed, even while it is snaked five or ten feet into a piece of machinery. Today, the most common RVI instrument is a video borescope, and most video borescopes on the market can be broken down into three main components: 1) The articulating tip, which contains the micro-camera, LEDs and “bending section”; 2) The insertion tube, which can range in length from a few feet to several meters, and can range in diameter from 3.9mm to 8mm; and 3) The base imaging unit, which houses the main PCB, camera articulation controls, video monitor and power supply.

For any technician who monitors, maintains or repairs complex machinery or equipment, nothrep in aids the diagnostic process more than being ing able to see the physical condition of critical comabl ponents. Unfortunately, this often means tearing pon down dow an engine, disassembling a machine or shutting down an assembly line, all of which cost precious time and money. And while there are other instruments and methods than can sometimes help determine the condition of wearing components– think eddy current or radiography, for example–nothing is quite as useful as a visual inspection. This is where the newest advancements in remote visual inspection (RVI) technology can have a huge impact on maintenance and repair expenses and, most critically, downtime. RVI instruments have existed for nearly a century and, while the technology behind RVI has The videoscopes insertion certainly evolved, the basic goal tube can range in length remains the same: to see into plac- from a few feet to several es an operator’s eyes cannot. The meters, and can be made pathway to today’s state-of-the-art of braided, stainless-steel RVI instruments has evolved from tubing. Source: RF System Lab

16 NDT ● OCTOBER 2011

NDT SPECIAL SECTION

The articulating tip of a videoscope contains the micro-camera, LEDs and “bending section.” Source: RF System Lab

Why RVI? In addition to the obvious advantage of being able to see things operators could not otherwise see without time-consuming disassembly, there is another key reason to consider adding a modern video borescope to your tool kit, and that is the ability to document, through pictures and video, the condition of the inspected compowww.ndtmag.com

nents. Visual documentation can serve three important purposes. First, pictures can be used to help explain to a customer why certain repair work needs to be done. It’s one thing to read an oil analysis report that turns up metal shavings in gear box lubricant, it’s another to see a color photo of a bevel gear with missing teeth. Second, visual documentation provides an insurance policy against any potential misunderstanding or disagreement over component condition or service work justification. In the example above, if the customer sees the condition of his bevel gear, and still decides not to replace the broken gear, he will be hard-pressed to come back to the service technician three weeks later when the gear strips out entirely and claim he was not properly informed of the severity of the problem. Forewarned is forearmed. The third reason is, when used over time, visual documentation can show the wear trends that occur with use. For example, by inspecting the stators of progressive cavity pumps at regular intervals–say every 10 hours of use–a technician can learn to gauge the remaining life of the stator and remove it from service before it chunks out on the job. Other types of inspections in which it is helpful to monitor and document the condition over time include engine valve inspections, boiler tube inspections and any inspection related to corrosion or accumulated blockage.

The base imaging unit houses the main PCB, camera articulation controls, video monitor and power supply. Source: RF System Lab

Industry and Product Trends One of the key trends occurring with video borescopes is the simplification of design in order to allow the technology to “trickle down” into applications that previously did not justify the expense. This same trend occurs in many other technical and consumer product categories, from flow meters and thermal imaging cameras to GPS and digital cameras. With technology in general, devices that at one time were very expensive and complicated tend to become more affordable and easier to use, opening the door to much wider adoption. In the case of video borescopes, this “trickle down” trend has been fueled by the ever-smaller and more powerful cameras developed for use in cell phones and laptop computers, as well as advancements in micro-LEDs www.ndtmag.com

Many videoscope models offer joystick camera-articulation control. Source: RF System Lab

that deliver the necessary illumination. The result is that there are now video borescopes that deliver all of the key features–joystick articulation control, direct micro-camera imaging, on-board photo and video storage–at a fraction of the price seen only five years ago. We can see this trickle down effect, for example, in aviation MRO centers, where, until recently, only technicians in the engine shop used borescopes because of their cost, complexity and lack of portability. Now, because borescopes are less expensive, more portable and

easier to use, their use is being extended to inspections of airframes, instrument panels, flap tracks and even ground support equipment. In other industries, borescopes are being used to inspect gear boxes, internal welds, pump vanes and combustion chambers in reciprocating engines. These are all applications for which the use of a borescope would have been cost prohibitive just a few years ago. Another important trend is an increase in the portability of full-featured video borescopes. Gone are the days when a user had to pull out a large cart-mounted system just to do a quick inspection. Today’s scopes take advantage of the miniaturization that has occurred in camera and lens design, as well as the latest techniques in image processing and PCB manufacturing. What used to weigh 30 lbs., require a 120 volt wall outlet and come in its own suitcase now weighs less than 2 lbs. and runs on AA batteries. In the aviation industry, this means that a full-featured borescope can be transported as carry-on luggage when a tech has to travel to an AOG (aircraft on ground) location. Additionally, in such a situation, any photos taken with the scope can be easily emailed back to the shop for analysis or a second opinion. Thanks to the increased portability, ease of use and lower cost of modern video borescopes, this technology is finding its way into many industries that have multiple, geographically dispersed locations, including onshore and offshore drilling rigs, natural gas compressor stations, heavy-equipment service trucks and small power-generating facilities.

TECH TIPS ● Today’s videoscopes weigh less than 2 lbs. and run on AA batteries. ● Choose a scope that has the critical features needed, without going overboard on features or add-ons. ● Be careful not to buy the cheapest scope. ● Take into account the total cost of ownership, which includes not only the acquisition cost, but also repair costs, maintenance and training.

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Choosing the Right Scope In selecting the right video borescope application, it is important to choose a scope that has the critical features needed, without going overboard paying for features or add-ons that are unneeded or rarely used. For example, one feature available on some high-

end video borescopes is referred to as a “measurement function.” This is an expensive add-on, but it can be worthwhile in certain applications, such as in the inspection of turbine aircraft engines, where tolerances for defects or damage are spelled out by the manufacturer. When there is a question as

S1 TURBOSD Technology you can trust

to whether a certain defect is within tolerance, a measurement function can help determine the answer. As anyone in the aviation MRO industry will tell you, repair work on an aircraft engine is very expensive, so the added cost of a measurement function on a video borescope can be worthwhile. While it is important to not buy a more complex or expensive borescope than needed, be careful not to buy the cheapest scope. A good understanding of basic requirements–the length and diameter of your access path, whether or not you require camera articulation, or how close you are able to get the camera to the inspection target–can help zero-in on an appropriate scope through a simple, five minute conversation with a knowledgeable sales rep. As with anything, try before you buy, and some companies will even ship a no-cost demo unit to evaluate in-house before making a buying decision. A final consideration in selecting a borescope is the total cost of ownership, which includes not only the acquisition cost, but repair costs, ongoing maintenance costs and costs to train new employees on the system, if required. These items can add up over time, so be sure to inquire about these expenses when shopping for the right system. Also ask about warranty coverage and whether a loaner is available if the scope should need service.

Bottom Line s Fast alloy ID and chemistry s Completely non-destructive s Prevents material mix-up

The S1 TURBOSD XRF analyzer uses innovative SDD technology which provides fast and accurate alloy analysis. www.bruker.com/hhxrf [email protected]

Innovation with Integrity

18 NDT ● OCTOBER 2011

Handheld XRF

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The fast pace of technological change brings with it many challenges, especially to those responsible for maintaining the performance and quality of complex machinery, equipment and processes. It’s nice when that same technological evolution delivers an instrument or tool that helps make the job easier. Such is the case with today’s video borescopes. If it has been more than three or four years since you explored this category, take a look at what’s new. It’s surprising what’s out there, and amazing how it can make the job easier. NDT Sean O’Connor is General Manager of RF System Lab. [email protected] www.ndtmag.com

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SORTING AND CONTAINMENT SERVICES

Using Radiography Lab services can help guard against a product defect is not discovered until well after the part is already on trailers, in transit, on the customer’s floor or in assembled products such as vehicles. By Mike Forbes

D

Despi all the planning and due diligence in the Despite Desp pre-launch control plan, production issues can pre-la occur. occur ccur While adhering to JIT and lean manufacturprinciples can lower production costs, the necesing ng pr sitated minimal inventory volumes can magnify the sitate cost of o faulty products entering the supply chain. Often, a product defect is not discovered until well after the part is already on trailers, in transit, on the customer’s floor or in assembled products such as vehicles. However, a lab services team can travel to the location of the product to provide on-site inspection, sorting and containment services to minimize possible production disruptions.

• Dense material contaminate, i.e. food products, screws/metal shearings • Circuit boards, i.e. bad soldering points, missing components • Numerous other nonconformance issues Real-time radiography is not without limitations, but is a very efficient methodology. Some of the limitations are due to the density of products surrounding the area of interest and the permanent record is not as clear as film radiography. However, flawed products can be sorted and further examination can be performed utilizing other methods. Regardless of the issue, sorting numerous amounts of product in a quick, clean, safe and cost effective way keeps the supply chain moving without having costly downtime or shutting down a major supplier.

Computed Radiography Computed radiography (CR) is a technique that

Real-Time Radiography Real-time radiography is a non-destructive testing method that is capable of viewing a radiographic image in real time without the hindrance of developing film or having to deal with hazardous chemicals. It has the capability to magnify the area of interest, making the interpretation of an indication a much easier process. This process is called micro focus. When a product has been quarantined or contained, radiography is a method that can be utilized to sort the product, separating the “flawed suspect” and verifying “good” product. Real time is a more cost effective method, since multiple parts can be ran continuously without the material cost of film and chemicals. Types of Product Sorting Utilizing Real-Time Radiography • Aluminum Cast Products • Electrical Components, i.e. bad connections • Enclosed mechanical devices, i.e. missing components 20 NDT ● OCTOBER 2011

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X-ray technology of this metal component helped identify noticeable voids. Source: TUV Rheinland Industrial Solutions www.ndtmag.com

• Easier documentation and retention of welder qualifications. • Enables electronic or DVD transmission of inspection reports, as well as simultaneous viewing by people in multiple locations.

Gamma Radiography

Sorting numerous amounts of product in a quick, clean, safe and cost effective way keeps the supply chain moving without having costly downtime or shutting down a major supplier. Source: TUV Rheinland Industrial Solutions

captures a radiographic image in storage phosphors for later readout and display. Unlike “prompt-emitting” phosphors used in conventional phosphor-intensifying screens, these storage phosphors retain the latent image, which remains stable for a period of time before it decays to a level at which image quality will be adversely affected. This period can range from minutes to days, depending on the screen phosphor material. During this time, the image can be read out with a scanning system, which, through the application of appropriate software, digitally reconstructs the radiographic image. The image is read out by scanning it with a red or near-infrared light to stimulate the phosphor, causing it to release its stored energy in the form of visible light. This phenomenon is known as photo stimulable luminescence. Like conventional intensifying screens, the intensity of this stimulated luminescence is directly proportional to the number of X-ray photons absorbed by the storage phosphor. www.ndtmag.com

Why Consider Computed Radiography? Computed radiography enthusiasts cite a number of attractions: • Greater dynamic range of phosphor plates compared to film, allowing more range in the depth of the material being examined. • Reduced exposure times and reduced energy requirements. • Quicker results without chemical processing—images on the phosphor plates are scanned, retrieved and stored digitally. • Fewer return trips for reshoots due to artifacts on film or exposure errors. • Reduced footprint in the lab for image processing. • Decreased archiving facility requirements. • No film or associated costs—phosphor plates last thousands of exposures with respectful handling. • No photographic chemicals or associated health and environmental concerns.

Gamma Radiography can be used in the laboratory (shooting vault) or in the field. It is used to shoot through thick product—three inches or greater of steel or large parts that are not easily moved. This process uses gamma ray radioisotopes to test materials for f laws such as invisible cracks, defects and occlusions in the quality of welds. The advantage of gamma radiography compared to non-nuclear technologies is that it can be done thoroughly and non-invasively (one does not have to cut the material). It can be done rapidly and, in some cases, is less expensive to perform. The process is very similar to X-ray radiography in a hospital or X-ray screening of luggage at an airport. The difference is that instead of using X-rays, gamma radiography uses a source that is more penetrating, such as cobalt-60. Radioisotopes have an advantage in that they can be taken

TECH TIPS ● Always choose an accredited agency ● Make sure they use only qualified, level-II inspectors and cost-effective, highly trained personnel ● Ensure they are third-party certified (report) ● Ask if they provide traceable documentation

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AUTOMOTIVE FOUNDRIES & CASTINGS FOOD WELDING (SPOT WELD) ELECTRICAL COMPONENTS POWER GENERATION PHARMACEUTICAL

CRITICAL COMPONENTS CRITICAL COMPONENTS CONTAMINATION WELD QUALITY / FAILURE CRIMPED WIRES / BAD SWITCHES PIPELINE CORROSION PROCESS PIPING & PRODUCT CONTAMINATION

Just released

SNT-TC-1A

Typical non-destructive radiography inspections by industry type. Source: TUV Rheinland Industrial Solutions.

Recommended Practice No. SNT-TC-1A 2011 Edition, Personnel Qualification and Certification in Nondestructive Testing

This revision provides updated training and certification requirements for Level I, II and III personnel. New content on: • Guided Wave and Ground Penetrating Radar as Methods • Radiological Testing Method which includes; • Radiographic Testing • Computed Radiography • Computed Tomography • Digital Radiography • Ultrasonics, Time of Flight Diffraction and Phased Array as Techniques • Additional Example Questions

See this publication and more at ShopASNT online at www.asnt.org/shop/ Phone FAX Mail

(614) 274-6003, (800) 222-2768 for US and Canada, (614) 274-6899 The American Society for Nondestructive Testing P.O. Box 28518, Columbus, Ohio USA 43228-0518

22 NDT ● OCTOBER 2011

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to the site when an examination is required and no electric power is available. All that is needed to produce effective gamma rays is a small pellet of radioactive material in a sealed titanium capsule. The capsule is placed on one side of the object being screened and photographic film is placed on the other. The gamma rays, like X-rays, pass through the object and create an image on the film. Just as x-rays show a break in a bone, gamma rays show f laws in metal castings or welded joints. The technique allows critical components to be inspected for internal defects without damage and in place.

Film X-Ray Radiography Traditional film radiography is a nondestructive failure analysis technique used to examine the interior details of an item. It operates on the principal of dissimilar transmission of X-rays through different materials. The ability of a material to block X-rays increases with its density. It is this dissimilar transmission of X-rays through different materials that is utilized to create an image of various contrasts. X-ray imaging may be accomplished on film. The interior parts of an item are exposed to radiation and the film is then developed through the chemical and drying process. The image is then viewed with a high-intensity light and compared to a reference standard.

The Importance of Selecting the Right Inspection Company When panic situations occur, a carefully selected partner in inspection can limit exposure to losses and down time. Always look for the following when choosing a lab services partner: • Accredited agency • Qualified, level-II inspectors • Third-party certification (report) • Cost-effective, highly trained personnel • Traceable documentation NDT

Mike Forbes is National Sales Manager of TUV Rheinland Industrial Solutions (Formerly Non-Destructive Testing Services) (800) 748-0208

www.ndtmag.com

Many products have internal bonded interfaces between materials and the problem for assemblers is determining whether the materials are truly bonded over an adequate area. By Tom Adams

T

The defects that attack bonds may be called disbonds (never bonded), delaminations (bonded, b bond broken loose), voids (air bubbles), cracks t then or ssome other term, but they all can be relio ability killers. a abili The T reason for wanting to find these gap-type defects is often to preserve strength, structural integrity and, in some cases, thermal conductivity. Suppose a product includes a polymer layer bonded to a metal layer. Because a polymer is very transparent to X-ray, disbonds and other gaps will be hard to see. If both layers are metal, a gap might be visible in the X-ray image, especially if the gap is thick relative to the whole thickness of the part. If the part is, say, 1-cm thick and between two metal layers and there is a void gap only 10 microns thick, the “missing material” represented by the void is too insignificant to create contrast in the X-ray image. Alternately, engineers could cut through the part and polish the exposed surface, but if the gap is small enough it may be filled-in and obscured by the polishing process. And the cutting process destroys the part. There are many instances in which the same part can be imaged by either X-ray or acoustic microscopy, especially where the suspected defect is not extremely thin. X-ray and acoustic microscopy are thus said to be complementary methods. Acoustic inspection of materials takes three general forms, depending on the frequency of

www.ndtmag.com

ultrasound being used. Ultrasonic testing uses a probe to create an echo that is interpreted and uses fairly low ultrasonic frequencies. Ultrasonic imaging (such as medical ultrasound) uses somewhat higher frequencies, up to perhaps 20 MHz and converts echoes into pixels to make a visible image. Acoustic microscopes use higher-frequency ultrasound from 15 up to 400 MHz and above to produce high-resolution acoustic images. An acoustic microscope system uses a focused transducer that raster-scans the top surface of the part at speeds up to 40 inches per second. Frequencies up to 300 MHz are designated as Very High Frequency; those above 300 MHz are Ultra High Frequency. As the transducer moves across the part, it sends a few thousand sequen-

Voids (red in the acoustic image) compromise the bond of an X-ray target to its substrate. Source: Sonoscan

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to 400 MHz) penetrate less tial pulses of ultrasound per but have greater resolution. second into the part. Most samples have one The ultrasound that an flat surface that is scanned by acoustic microscope pulses the transducer, but cylindriinto the sample is ref lectcal, spherical and even conied from material interfaccal samples can be imaged. es, but it is ref lected with Figure 1 is the acousmaximum amplitude from tic image of the interface gaps—cracks, disbonds and between two metal pieces the like. A few microsecholding a flexible diaphragm onds later, the return echoes in place. The purpose of from material interfaces at acoustic imaging was to various depths within the determine whether the seal part arrive back at the transat the edges of the diaphragm ducer, the exact arrival time was good. The diaphragm, depending on the depth of at bottom, appears somewhat the interface from which the Acoustic image and side-view diagram of diaphragm held between two bar. White areas in the acoustic image show where wavy because it produces an pulse was ref lected. interference pattern. The Where a polymer layer metal bars are not bonded to the edge of the diaphragm. Source: ultrasonic pulse has traveled is bonded to a metal layer, Sonoscan through the bulk of the top the percent of pulse energy metal piece, and echoes are ref lected by the interface reflected from the metal-diacan be calculated by knowphragm interface. ing the properties of the Where the two plates are two materials—the percentwell-bonded to the edge of age may be 15, 35 or 60, the diaphragm, the interface for example. Some of the are light gray. The irregular energy will travel deeper and white areas are disbonds. A may be reflected by a deeper few small scattered disbonds material interface. might not be critical, but If part of the area where these disbonds come close to the polymer should be bondforming a continuous pathed to the metal is disbanded, way from the diaphragm to delaminated or contains a the exterior. Vibration, thervoid or crack, then the intermal cycling or other factors face that the pulse hits will Red areas are heat-blocking voids between a heat sink and two could cause a leak, which be polymer-to-air instead of ceramic plates. Source: Sonoscan would result in a perforpolymer-to-metal. The properties of a gas such as air are so differIn the acoustic image, the bonded mance failure. This disbonded area is a ent from the properties of a solid that polymer-to-metal areas will be some good example of a defect that would be 99.99% of the pulse will be reflected. shade of gray, but the defect will be very difficult to detect by other methods. bright white, indicating the highest The acoustic image shows the extent of ref lection amplitude. It is the solid-to- the disbond and may give clues about the air interface that does the ref lecting. processing error that caused the disbond. An X-ray target is shown in Figure 2. Within limits, the thickness of the gap ● A 10-micron thick void is too is unimportant; at the frequencies used In an X-ray system, the target is a dense insignificant to create contrast in the in acoustic microscopy, a gap 1-mm metal element mounted at a 45° angle X-ray image. thick will have the same brightness as a to the electron beam coming from the anode. Some of the electron beam is gap