Quality February 2012

FEBRUARY 2012, VOLUME 51/NUMBER 2 WWW.QUALITYMAG.COM

. po

co

m

ex ur er 12 ov 0 f C 2 k u an 2, ac y m a eB h ec M sid t . In w e w w Se t ac

Air Gaging

Customizable to Meet Your Application Needs ‡ High performance in tough environments ‡ More air gage display choices ‡ New portable air gaging solutions ‡ Easy to use submicron inspection of critical diameters and tapers ‡ Fast special application solutions ‡ Available for fast delivery

-

+ PRECISION GAGES

SNAP GAGES

AIR GAGING

SURFACE MEASUREMENT

FORM MEASUREMENT

GEAR MEASUREMENT

PRECISION LENGTH MEASUREMENT

Mahr Federal - The Application Specialist Contact: Mahr Federal Inc., Providence, RI Phone 800-343-2050, Fax 401-784-3246, E-mail: [email protected], Internet: www.mahr.com

TABLE OF

CONTENTS QUALITY MAGAZINE

|

FEBRUARY 2012

|

VOLUME 51

|

NUMBER 2

DEPARTMENTS

28

6

FROM THE EDITOR

Numbers 8

INDUSTRY NEWS

Airbus Delivers 7,000th Aircraft The Snake Returns to Chrysler Manufacturing Technology Demand Strong 16 FACE OF QUALITY

Focus on the Vital Few, Part II 18 OTHER DIMENSIONS

Does New Stuff Have to be Calibrated? 20 LEGAL INSIGHT Source: Faro

Choosing Between a Corporation and LLC 22 GD&T WORKSHOP

The Perfect Imaginary World of GD&T 24 QUALITY 101

FEATURES

21st Century Optical Comparators

QUALITY MEASUREMENT

28 THE DEMOCRATIZATION OF MEASUREMENT Smaller and more affordable 3-D measurement technology is changing the job descriptions of level 1 operators.

QUALITY TEST & INSPECTION

32 SENSING THE THREAD Inductive displacement sensor technology is used for thread detection.

QUALITY SOFTWARE

34 GOOD DATA = GOOD DECISIONS Measurement system analysis helps to judge whether an attribute gage is trustworthy.

26 QUALITY INNOVATIONS

QI Macros Focus on “Vital Few” Tools 44 CASE STUDIES

Software Brings New Business Greater Gains Through Digital Inspection 61 CLASSIFIEDS 62 QUALITY PRODUCTS 64 ADVERTISING INDEX

NEXT MONTH

QUALITY MANAGEMENT

36 QUALITY LEADERSHIP 100 Commitment to quality lands companies in the annual Quality Leadership 100 list.

Quality Plant of the Year Laser Trackers Shaft Measurement SPC

FEBRUARY 2012, VOLUME 51/NUMBER 2 WWW.QUALITYMAG.COM

ABOUT THE COVER More than 400 manufacturers participating in the Quality Leadership 100 were surveyed on criteria such as scrap and rework as a percentage of sales, warranty costs as a percentage of sales, rejected parts per million shipped and contribution of quality to profitability and shareholder value. Source: TRW Automotive

w

2

w

.te w

m co o. xp re er tu ac 12 Cov uf 20 ck an 2, m Ba ch May de si In e Se

QUALITY | February 2012

www.qualitymag.com

YOU COULD PLAY GOLF WITH JUST A PUTTER... BUT WHY WOULD YOU?

Keep Measurements up to Par With Hexagon Metrology Hexagon Metrology is your partner for the largest selection of products and services under one roof. With so many options to choose from, there are standard solutions available for your measuring tasks. However, if one size doesn’t fit all, we have the expertise and resources to custom build a solution for your unique application. To learn more about solutions that fit your needs, scan this code with a smart phone or visit www.HexMet.us/metrology.

H e x a g o n M e t r o l o g y, I n c . | 2 5 0 C i r c u i t D r i v e | N o r t h K i n g s t o w n , R I 0 2 8 5 2 | w w w. h e x a g o n m e t r o l o g y. u s

QUALITYMAG.COM

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

Available On-Demand Cognitive Biases and Project Planning Cognitive biases are more common than we imagine, even among folks who are technically well-trained and competent. These can lead to misreading data and faults in project planning. Deming’s Seven Deadly Diseases of Management W. Edwards Deming’s “14 Points” express his philosophy of management. Specifically, they break down the need for a working understanding of basic quality management system statistical principles. In addition to the 14 points, Deming outlined seven deadly diseases that describe the most serious barriers that management potentially faces within an organization. Increasing Process Profitability through Insight from Visual Management Kaizen, lean manufacturing, Six Sigma, total quality management, continuous improvement—all of these terms refer, in some form or another, to the efforts of companies as they strive to become more competitive in a global economy.

Industry experts share their views on the latest in quality and manufacturing:

• Quality Remix

• Jim’s Gems: Weekly Updates!

• Learning with Lecky, Vision RoundUp and Perspectives in Vision

• Shifting the Paradigm

CAD-Based Inspection Using Contact Measurement Eddy Current Testing: Its Many Benefits and Applications 3-D Optical Microscopy— Correlating Industrial Surface Metrology to Enhanced Product Performance

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

• NDT: Key to Quality and NDT Round-Up

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

If you missed Quality Expo, or want to

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

4

QUALITY | February 2012

revisit it, see videos from: • • • • •

Mahr Mitutoyo Scienscope Siemens S-T Industries

www.qualitymag.com

Look closer.

Optically measure complex shafts in seconds. Diameter, length, geometry and form. Automatically. To microns. ■

CNC flexibility to handle any shaft

■

Submicron repeatability Simple, high-speed operation ■ Easy to program ■ Shop-floor ready ■

With Hommel-Etamic, your production quality never had a greater chance for improvement. For measurement reliability, uncompromised precision, and worldwide technical support, call on Hommel-Etamic.

Industrial Metrology Division

Hommel-Etamic 1505 West Hamlin Rd, Rochester Hills, MI 48309 Tel: 248-853-5888 Fax: 248-853-1505 www.hommel-etamic.com

Precision is Our Business.

FROM THE EDITOR

NUMBERS

CONTEXT AND ANALYSIS ARE KEY TO THEIR UNDERSTANDING.

I

If this were TV or radio, this is when you would hear the theme song from “Jeopardy,” but since this is print, I’ll just ask, “Do you have it?” It’s the number 194. This is just one example of “numerous” number riddles. They are designed to test logic and, in many cases, trick the mind. To a lesser extent, these riddles remind me of those middle school word problems. You remember them. They usually start out with a train leaving Chicago traveling to Philadelphia at 60 mph, another leaving Philadelphia bound for Chicago at the same time traveling 80 mph and a question asking which of the trains will arrive at its destination first. The problem also will tell the reader how far these cities are from one another, but invariably the problem also will contain information that is of no concern to the question. The folks who design these questions are not necessarily trying to trick the reader, but focus attention on context—what matters to the question.

4 12

8

4

3

6

7 6

8

DARRYL SELAND

Context and focus. They are a major tenant of logic. A pile of numbers is just that, a pile. Without context and analysis, they mean nothing. The information that doesn’t matter to the task at hand is just noise. But we take this pile and give it context and analyze what it means and we gain knowledge. And knowledge is power. So, I invite you to feel powerful about the subject of leadership with the analysis of Quality’s Leadership 100 Survey and how good data means good decisions with this month’s Quality feature article, "Good Data = Good Decisions." In addition, this month’s Quality Innovation discusses software that easily compiles data and automatically transforms the data into well-known chart formats for easy analysis. As always, enjoy and thanks for reading!

5 7 9 3

am a three digit number. My tens digit is five more than my ones digit. My hundreds digit is eight less than my tens digit. What number am I?

Darryl Seland, Editor in Chief

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

Proud Members of

Official Sponsor of

BNP MEDIA HELPS PEOPLE SUCCEED IN BUSINESS WITH SUPERIOR INFORMATION

FOR SUBSCRIPTION INFORMATION OR SERVICE, PLEASE CONTACT CUSTOMER SERVICE AT: TEL. (847) 763-9534 OR FAX (847) 763-9538 OR E-MAIL [email protected]

6

Darrell Dal Pozzo, Group Publisher [email protected]

James P. Hohner Jr., Art Director [email protected]

Barbara Grim, Associate Publisher [email protected]

Karen A. Talan, Production Manager [email protected]

Darryl Seland, Editor in Chief [email protected]

Jill L. DeVries, Reprint Manager [email protected]

Gillian Campbell, Editor [email protected]

Christopher Wilson, BNP Custom Media Group (248) 244-8264, [email protected]

LIST RENTAL Kevin Collopy, Sr. Account Manager Phone: 845-731-2684, Toll Free: 800-223-2194, ext. 684 Email: [email protected]

Genevieve Diesing, eMedia Editor [email protected]

Ann Kalb, Single Copy Sales P: 248-244-6499 F: 248-244-2925 [email protected]

Shawn Miller, Account Manager Phone: 845-731-3828, Email: [email protected]

QUALITY | February 2012

AUDIENCE DEVELOPMENT Christopher Sheehy, Audience Development Manager Katie Jabour, Multimedia Manager Catherine M. Ronan, Corporate Audience Audit Manager

CORPORATE DIRECTORS Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Information Technology: Scott Krywko Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Events: Scott Wolters Clear Seas Research: Beth A. Surowiec

www.qualitymag.com

Measuring Force & Torque? Just Plug & TestTM!  : (

1

,QWURGXFLQJ DOOQHZ 3OXJ  7HVW70 7HFKQRORJ\ IURP 0DUN  DQ LQQRYDWLYH DQG IOH[LEOH IDPLO\ RI GLJLWDO IRUFHWRUTXH LQGLFDWRUV DQG LQWHUFKDQJHDEOH VPDUW VHQVRUV0HDVXUHXSWROE)>N1@RIIRUFHDQG XSWROE)LQ>1P@RIWRUTXHZLWKWKHLQGXVWU\·V EURDGHVW UDQJH RI VHQVRUV  DOO RI ZKLFK SOXJ LQWR RXU LQGLFDWRUV ZLWK DQ HQJLQHHUHG ´FOLFNµ DQ\ SURIHVVLRQDO ZLOODSSUHFLDWH6RWKHQH[WWLPH\RXUUHTXLUHPHQWVFDOO IRUPHDVXULQJIRUFHRUWRUTXHMXVW3OXJ 7HVW70 7ROHDUQPRUHFDOOXVDW0$5.7(1RU YLVLWXVDWZZZPDUNFRP

$'

)25&( 72548(0($685(0(17

IND IN DUSTRY

COMING EVENTS MARCH 14-15 QUALITY EXPO TEXAS Fort Worth, TX (310) 445-4200 www.canontradeshows.com/expo/qexpo_s12 18-21 FUSION 9 2012 USER CONFERENCE Clearwater Beach, FL (813) 915-1663 www.pilgrimsoftware.com 20-22 WESTEC 2012 Los Angeles, CA (800) 733-4763 www.westeconline.com APRIL 24 LEAN EXPERT TRAINING AND CERTIFICATION Atlanta, GA (800) 338-7726 www.juran.com/services_training_ public_workshops.html MAY 5-9 MANUFACTURING INNOVATION 2012 Orlando, FL (301) 975-4919 www.nist.gov/mep/mi2012.cfm 8-10 THE VISION SHOW Boston, MA (734) 994-6088 www.machinevisiononline.org

PEOPLE NEWS Tecumseh Products Co. (Ann Arbor, MI) appointed former company executive BILL MERRITT as president of its new business group. Merritt will lead Tecumseh’s United States, Canada and Mexico initiatives which collectively form the new region. He will to report to Jim Connor, president and CEO. MATT GARBARINO, a 20-year veteran of the metal fabrication industry, has been appointed marketing manager of Cincinnati Inc. (Harrison, OH), a builder of laser cutting systems, press brakes and shears. Garbarino has seven years experience in sales with Cincinnati and 13 years in various e-marketing, b2b Web businesses, and software companies serving the metal fabrication industry. Prior to re-joining Cincinnati in 2010, he founded TheFABZone.com and was president and COO of Machinetools.com. Carestream Tollcoating (Medford, OR), a provider of contract coating services, appointed RICK DANIELS to the executive advisory board for the Nanomanufacturing Center at UMass Lowell. Daniels leads Carestream’s Advanced Materials and Contract Manufacture business and is responsible for both contract manufacture and joint venture activity.

8

QUALITY | February 2012

BUSINESS NEWS | COMING EVENTS | PEOPLE NEWS | MERGERS

AIRBUS DELIVERS 7,000TH AIRCRAFT TOULOUSE, FRANCE—Airbus’ delivery of its 7,000th aircraft in December 2011 marked a new achievement as the company continues to accelerate the production output of its single-aisle and widebody jetliners in meeting demand from a widening global customer base. This delivery was a member of the A320 Family, which is one of the world’s best-selling commercial aircraft product lines—with more than 4,900 provided from the more than 8,250 ordered by 340-plus customers around the globe. The other Airbus aircraft contributing to this delivery milestone were its cornerstone medium-haul A300 and A310, of which 816 were supplied during its successful production run; the long-range A330 and A340, with 1,200-plus provided through the end of November 2011, along with the more than 60 very large A380 jetliners received by airlines through early December 2011. Overall, Airbus’ production output has been increasing since the company handed over its first aircraft in May 1974: an A300B2. In March 1993, the 1,000th delivery landmark occurred with an A340-300, followed by the 2,000th handover in May 1999, which also was an A340-300. Underscoring its rapid growth with an expanded aircraft family, the 3,000th Airbus aircraft delivery was an A320 provided in July 2002, while only three years later—in September 2005— an A330-300 became the 4,000th aircraft supplied to a customer. Just two years afterward, the 5,000th milestone was achieved in December 2007 with an A330-200. The 6,000th

delivery in January 2010—involving an A380—further confirmed the company’s continued leading role as a provider of highly efficient aircraft to airline operators and customers around the world. For the 7,000th jetliner handover in December 2011, the aircraft was an A321 provided to United States-based US Airways, which is one of Airbus’ biggest single airline clients, and also has the distinction of flying the largest A320 family inventory of any carrier.

THE SNAKE RETURNS TO CHRYSLER GROUP’S CONNER AVENUE ASSEMBLY PLANT AUBURN HILLS, MI—Chrysler Group LLC will reopen its Conner Avenue Assembly Plant in Detroit for the production of the next generation SRT Viper. With the plant’s reopening, nearly 150 jobs, both hourly and salaried, will return to the city of Detroit. The Conner facility was idled when production of the Dodge Viper ended in July 2010. “The next generation Viper will make its return to the product lineup in late 2012 as a 2013 model,” says Ralph Gilles, president and CEO, SRT Brand and Motorsports, Chrysler Group LLC. “We’re extremely excited that our ultimate American sports car will continue to live on and be produced exclusively here in the Motor City.” Current Chrysler Group hourly employees who previously worked at Conner were first offered the opportunity to return to their home plant. The balance of the positions will be filled by hourly employees volunteering to transfer to the Conner Avenue plant. Conner Avenue will begin building the new Viper in late 2012, but employ-

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.

www.qualitymag.com

ees began reporting for training and orientation in the fall of 2011. In preparation for the reopening, the Conner facility will begin its transformation by implementing worldclass manufacturing, a system that is focused on reducing waste and making continuous improvements throughout the assembly process to improve quality and productivity. The Conner Avenue Assembly Plant was built in 1966 and purchased by Chrysler in 1995. Viper production began in May 1992 at the New Mack Assembly Plant and was moved to Conner Avenue in October 1995. Prowler production began in May 1997 and ended in February 2002. Viper V-10 engine production was transferred from Mound Road Engine to Conner

Assembly in May 2001. In 2003, the newly engineered SRT10 Roadster hit the market and the SRT10 Coupe followed in 2005. With a production run of 28,056, Viper production ended on July 2, 2010. As a result, the facility was idled.

MANUFACTURING TECHNOLOGY DEMAND STRONG AMID OTHER ECONOMIC WEAKNESS MCLEAN, VA—September U.S. manufacturing technology orders put the year-to-date total at approximately $4 billion, which is up 91.9% compared with 2010 and are the second highest dollar amount in the past 15 years. “It’s long been recognized that analysis of manufacturing technology orders provides a reliable leading economic indicator, as it is an indicator

that manufacturing firms are investing in capital equipment to increase their capacity and improve productivity,” says Patrick McGibbon, vice president, strategic information, research and membership for The Association for Manufacturing Technology (AMT). “Manufacturing technology provides a foundation for all other manufacturing. These machines and devices are the equipment that turn raw materials such as steel, iron, plastic, ceramics, composites and alloys from their original state as stock materials into what will become durable goods such as airplanes, cars and appliances, as well as consumer and other goods that are used every day.” The Midwest and central regions of the United States have seen the great-

VIDEO INSPECTION SYSTEMS

8700 SERIES WITH 4" x 8" OR 4" x 12" TRAVEL STAGES

9700 SERIES

9100 SERIES

WITH 12" x 12" TRAVEL STAGE

WITH 6" x 12" TRAVEL STAGE

./4%#/.3/,%"!3%/04)/.!,

All models have standard manual 2-axis or 3-axis stages with .00005"/.001MM resolution, LED substage and surface illumination, color camera and LCD monitor, 30-180X par focal zoom lens, electronic crosshair generator and choice of Quadra-Chek and M3 Touch Screen DRO’s. Also available with 2-axis or 3-axis joystick controlled motor drives or full 3-axis CNC joystick and trackball controls, video edge detection, image capturing, auto focus and programmable lighting.

S-T INDUSTRIES, INC. !RMSTRONG"LVD.s3T*AMES -.  s&AXsSALES STINDUSTRIESCOM

www.stindustries.com www.qualitymag.com

MADE IN U.S.A.

See the Quality February 2012 | QUALITY

9

IND IN DUSTRY

NEWS est surge in manufacturing technology orders. The Midwest’s manufacturing technology orders in 2011 are 120% more than the comparable figure for 2010. This large increase is the result of the region’s large traditional customer base. It also is where the oldest equipment resides and the industries impacted most by the weak dollar and on-shoring trend are located. The central region pick up—92% higher compared to

Does your SPC software help you win new business? If not, contact Zontec. “Synergy 2000 provides us that edge to win the business.” – Douglas Winfrey, Director of Quality for United Gear and Assembly

To gain that edge, call us at 866-955-0088 or visit us at www.zontec-spc.com.

10

QUALITY | February 2012

2010—was powered by the growth in the energy business and secondly by the automotive industry. “The factors that are fueling this tremendous surge are the traditional reasons that drive growth in investment, but what is unusual about the current rebound is that all factors have come together at one time. This is something that’s never been seen before,” McGibbon notes. “American manufacturers are still rushing to beat the end-of-year bonus depreciation deadline,” he continues. “Inventories were low—something we’ve never experienced going into a recession—and that accounts for the quick rebound. Exports are rising as American manufacturers meet overseas demand. Manufacturing technology from the United States is less expensive than foreign equipment, and U.S.-made goods are more price competitive than many imports due to the weak dollar.” The average age of machinery currently in use at U.S. manufacturing facilities crept up from nine years in 2007 to 13.5 years, and as demand started to increase the need for investment to replace the aging equipment became apparent. Those investments are being made in completely new technology. Multi-operation machines are profoundly impacting productivity. Water jet cutting and hydroforming are experiencing massive growth because they offer all the benefits of traditional processes but eliminate distortion and deformation. Additive manufacturing is growing, nano machining has become commercially affordable, and the availability of new materials, such as compact powdered metals, is having a tremendous impact. Plus, the emergence of cloud manufacturing, which promotes collaborative efforts across organizations, is opening new doors to manufacturers. Expanding markets worldwide are playing an important role as manufacturing grows. China seems insatiable and accounts for almost one half of the world’s total consumption of manufacturing technology. India’s economy is growing at double the Western economy’s rate, with expectations for more China-like development soon. As it prepares for major world events including the Olympics and the FIFA World Cup competition, South America faces the challenge

www.qualitymag.com

IND IN DUSTRY

NEWS of building infrastructure that can support the events. Russia, South Africa, the Middle East and South Asia are on the fringe, but nevertheless contribute to growth in the global manufacturing economy. Another factor boosting U.S. manufacturing is onshoring. More work is coming back to the United States from foreign shores, and there is greater foreign direct investment in U.S. facili-

ties. Why? The quality of work in the United States is proving to be more valuable than originally thought in the off-shoring investment calculation. Companies face increasing costs in logistics issues with the delivery of components and the exporting of completed products to North America. Add to that the rapidly increasing labor costs in traditionally “low-cost” labor markets, and the continued decline

VisionGauge

®

MITUTOYO AMERICA NAMES NEW PRESIDENT

Digital Optical Comparator

AURORA, IL—Shigeyuki Sasaki has been appointed the new president at Mitutoyo America Corp., headquartered in Aurora, IL. Sasaki has served numerous roles within Mitutoyo for the past 35 years including new product development and quality control departments in Utsunomiya, Japan; manager of purchasing and planning in Mitutoyo Germany; general manager in Mitutoyo South America; and recently vice president and executive vice president of Mitutoyo America. He will remain an active member of Mitutoyo’s board of directors. Sasaki succeeds Mikio Yamashita, who served as president of Mitutoyo America since 2006. Yamashita returned to Mitutoyo headquarters in Kawasaki-shi, Kanagawa, Japan at the end of 2011. John Westhaus, formerly vice president of capital equipment sales, will assume Sasaki’s role of executive vice president.

(Patent Pending)

The Fastest, Easiest, Most Accurate Way to Compare a Part to a CAD File™

t

'VMMZ
EJHJUBM t

)JHIFS
BDDVSBDZ t

"VUP
1BTT

'BJM
t

)JHIFS
UISPVHIQVU t

4NBMMFS
GPPUQSJOU t

0QFSBUPSJOEFQFOEFOU t

"VUPNBUJDBMMZ
DPNQVUF



EFWJBUJPOT
GSPN
OPNJOBM t

6TFT
FYJTUJOH
$"%
EBUB




/P
NPSF
PWFSMBZT t

$BO
FBTJMZ
CF
NPWFE t

$PMMFDU
DPNQMFUF
FMFDUSPOJD




EPDVNFOUBUJPO

EFWJDF
IJTUPSZ t

"WBJMBCMF
JO
CPUI
IPSJ[POUBM




BOE
WFSUJDBM
DPOGJHVSBUJPOT

FAURECIA AND FORD MOTOR CO. EARN SPE GRAND AWARD

VisionGauge

®

8FC
XXXWJTJPOYJODDPN &NBJM
JOGP!WJTJPOYJODDPN 5FM



12

QUALITY | February 2012

of labor in the overall share of total production cost, and the on-shoring picture becomes clear. The outlook for 2012 remains positive. Energy will continue to be a large investor in manufacturing technology. The automotive industry is making major changes to address green issues, which will lead to significant investments in production technology, as well as spending to support the shift of the industry’s center from Detroit to the South/Southwest. Aerospace green field investments will continue in the Southeast and West.

NANTERRE, FRANCE and AUBURN HILLS, MI—Faurecia, the world’s sixth-largest automotive supplier, was awarded top honors from the Automotive Division of the Society of Plastics Engineers (SPE) for Faurecia Interior Systems’ work with Ford Motor Co. on the 2012 Ford Escape compact SUV & Kuga compact CUV. The companies earned SPE’s Grand Awards for Process/Assembly/Enabling Technologies and the overall Most Innovative Use of Automotive Plastics in 2011. The awards were presented during SPE’s 41st Annual Innovation

www.qualitymag.com

Awards Competition and Gala in November 2011. “This MuCell instrument panel is the largest automotive component molded in the patented MuCell injection-molded process, as well as the first instrument panel to be molded in this process, a tremendous achievement for Faurecia and Ford,” says Jean-Michel Renaudie, president of Faurecia Interior Systems, North America. “In an industry that is highly impacted by volatile gas prices and stricter regulations, every ounce saved on a vehicle makes a difference. This process has enabled us to remove more than one pound of weight from the vehicle and save time on production.” MuCell involves the addition of a gas into the molded part during the injection process, which reduces the overall weight of the part because less plastic is used, while still maintaining the performance of the finished part. This helps Ford meet vehicle weightreduction targets, which in turn helps improve overall gas mileage. Faurecia also received the Safety Innovation Award for its Reinforced Airbag Lid in Foam (RALF) featured on the global 2011 Ford Focus compact car. RALF enables vehicle designers and stylists more design freedom around the instrument panel (IP) without compromising consumer comfort and safety. Faurecia’s innovative RALF technology eliminates the need to provide room for a hard-cover airbag lid to open without damaging the windshield, providing the flexibility to help designers better apply their creativity to the IP’s design, function and space. The SPE Automotive Innovation Awards Competition started in 1970 to recognize the positive changes that polymeric materials were bringing to the automotive industry, such as weight reduction, parts consolidation and enhanced aesthetics and design freedom. SPE’s Automotive Innovation Awards program is the oldest and largest competition of its kind in the automotive and plastics industries.

DETROIT THREE AUTOMAKERS TO HIRE THOUSANDS IN COMING YEARS

ing years of declining employment in the ranks of Ford Motor Co., General Motors Co. and the Chrysler Group LLC, according to Kristin Dziczek, director of the labor group for the Michigan-based Center for Automotive Research (CAR). Data from CAR indicate total employment of the Detroit Three automakers will increase from today’s 171,000 to 201,000 by 2015 and that

auto-industry suppliers will need to add from 100,000 to 150,000 new workers over the same period. But the research group’s projected 2015 total employment figure for the Detroit automakers still pales in comparison to the industry’s heyday. In the late 1970s, the Detroit Three employed more than 1 million workers in the United States. The industry-wide rehiring also will pressure the automak-

SEE US AT MD&M WEST, BOOTH 3031

DETROIT—Detroit-based automakers will hire more than 30,000 new workers in the next four years, revers-

www.qualitymag.com

February 2012 | QUALITY

13

IND IN DUSTRY

NEWS ers to address the existing two-tier wage structure with the United Auto Workers union, which is expected to be a point of increasing tension in coming years, particularly if the automakers continue to maintain their profitability trends. Currently, newly hired UAW workers start at an average of about $14 per hour, about half of what tenured union workers earn. The recently ratified labor contracts between the UAW and the Detroit

automakers do provide for gradually raising the figure to about $19 per hour by the end of the contract in 2015.

NISSAN AND DAIMLER TO PRODUCE ENGINES TOGETHER IN NORTH AMERICA DETROIT—In the latest step forward in the collaboration of the Renault-Nissan Alliance and Daimler, Nissan’s Decherd, TN, plant will build

Micro•Vu Precision Measurement Systems 13 New Machine Models NEW

NEW

Vertex 251 250x160x160 mm Automated 3D Starting at $32,000

Excel 501 500x400x160 mm Automated 3D Starting at $43,000

Systems Include

NEW

InSpec Metrology Software Advanced Vision Tools Programmable Lighting Programmable Zoom Automated Reporting Free Updates

NEW Excel 1001 1000x1000 mm NEW Excel 1601 1600x1000 mm NEW Excel 1651 1650x1250 mm 160, 250, and 400 mm Z available

Vision

Sol 161 160x160x160 mm Manual 3D, Auto Zoom Starting at $12,000

Touch

Laser

Established 1959

www.microvu.com 14

QUALITY | February 2012

Micro-Vu Corporation 7909 Conde Lane Windsor CA 95492 1-707-838-6272 [email protected]

Mercedes-Benz 4-cylinder engines for Infiniti and Mercedes-Benz starting in 2014. Nissan and Daimler will produce Mercedes-Benz 4-cylinder gasoline engines together at Nissan’s powertrain assembly plant in Decherd, TN. Production will begin in 2014, with installed capacity of 250,000 units per year once full ramp-up is achieved. The Decherd facility will produce engines for Mercedes-Benz and Infiniti models. “This is the newest milestone in our pragmatic collaboration and our most significant project outside of Europe so far,” says Renault-Nissan CEO Carlos Ghosn. “Localized capacity reduces exposure to foreign exchange rates while rapidly enabling a good business development in North America, a winwin for the Alliance and Daimler.” The collaboration marks the first production of Mercedes-Benz engines in the North America Free Trade region. The Tennessee plant’s strategic location and logistics links ensure a direct supply of engines starting in 2014 for the Mercedes-Benz C-Class, built at Daimler’s vehicle plant in Tuscaloosa, AL. “In the context of our MercedesBenz 2020 growth strategy, we have decided that we will expand the production capacities required for this close to the customers,” says Dr. Dieter Zetsche, chairman of the Daimler Board of Management and head of Mercedes-Benz Cars. “Through the strategic extension of our cooperation with Renault-Nissan, we can realize near-market engine production in the NAFTA region on attractive economic terms and make optimum use of synergies arising from the cooperation.” Nissan began powertrain assembly in Decherd in 1997. Today it manufactures 4-, 6- and 8-cylinder engines for the complete lineup of U.S.-produced Nissan and Infiniti vehicles. The plant also houses crankshaft forging and cylinder block casting operations. In 2011, Decherd produced more than 580,000 engines on a covered area of more than 1.2 million square feet.

FOR DAILY INDUSTRY NEWS, VISIT www.qualitymag.com www.qualitymag.com

EXPERTISE ACROSS THE SPECTRUM Introducing the new family of MTS monotonic testing solutions Leveraging decades of testing expertise and unmatched global support, MTS has expanded its extensive materials testing portfolio to include a versatile array of new monotonic testing solutions. Engineered to meet a full spectrum of materials testing needs, these new solutions include: » MTS TestSuite™ TW Software The latest, easy-to-use addition to the modular MTS TestSuite platform » MTS Criterion™ Universal Test Systems A complete line of high-performance electromechanical and static-hydraulic load frames, and full complement of accessories

©2012 MTS Systems Corporation. MTS is a registered trademark and MTS Criterion and MTS TestSuite are trademarks of MTS Systems Corporation in the United States. These trademarks may be protected in other countries. RTM No. 211177.

Contact MTS today and explore how new MTS Criterion Systems can enhance the flexibility and efficiency of your research, development or manufacturing testing programs. Visit us at TMS 2012, Booth #331 M AT E R I A L S T E S T I N G S O L U T I O N S

www.mts.com/expertise

FACE OF QUALITY

THE VITAL FEW, PART II IMPROVE PERFORMANCE AND IMPROVE QUALITY.

I

n last month’s column five tips were given for organizations and their quality professionals to consider focusing on to bring about positive results. Together, with these additional five tips, organizations will be well positioned to improve performance and improve quality.

JIM L. SMITH

6. Cost of poor quality (COPQ) must be known and managed. Most organizations have no idea of their total cost of poor quality. The cost of poor quality is defined as the costs that would disappear if systems, processes and products were perfect. There are few things that are perfect so every organization has a COPQ but precious few spend little time in trying to identify their COPQ. Dr. Juran and Philip Crosby said that the total COPQ can be as much as 25% to 30% of the cost of sales. Staggering! So why aren’t managers challenging their organizations to identify their COPQ and develop plans to improve? I don’t know the answer but most aren’t. This is hard to understand when every dollar of their COPQ saved goes straight to the bottom line. A couple years ago I spent time with a company that focused their entire continuous improvement efforts at the work team level. Their primary tool was a COPQ analysis worksheet to identify areas of waste. Everyone was trained, involved and worked toward reducing their COPQ. The result was sustained, and real improvement was pulled through to the bottom line. Quality improved, costs were reduced and jobs added in a competitive market. Everyone won. 7. Real improvement doesn’t center on hard assets. Organizations should determine where to focus their improvement efforts to get the greatest return. Typically, the tendency is to focus on hard assets. However, rather than just focusing on equipment and other hard assets, organizations would do well to put their continuous improvement initiatives toward people and processes. Organizations should implement disciplined dayto-day areas of review. In today’s lean manufacturing environment that effort would be part of the visual factory. Organizations should implement daily performance reviews to not miss opportunities for basic skills coaching, reinforcement and providing real-time feedback to and from the worker floor. 8. Enhance employee worth. Real, sustainable change can only happen in an environment where workers, supervisors and managers have real-time visibility into production performance, reduced

16

QUALITY | February 2012

administrative burden, and a structure that allows people to contribute their own ideas and turn them into actions. When employees feel valued and appreciated, they openly embrace their tasks with maturity and ownership. The key is to create an atmosphere of openness in a trusting climate that shows employees they have worth and value. To support this environment, organizations should implement an appropriate reward and recognition process that will translate into an empowered workforce. These actions will be responsible for releasing an explosion of creative solutions which will produce exponential results. 9. Focus on action. Don’t procrastinate. Decide the path that will achieve real improvement and focus on the implementation plan. With any performance improvement initiative momentum is key, and quick wins provide the fuel needed to gain momentum early on. Early successes ensure that the organization’s focus remains fixed on the true goals: higher quality with lower operating cost is the target, but don’t confuse the two as they are not always complementary. The proper resources need to be dedicated to making it happen. Too often organizations have great plans to create change but too few resources are actually committed and the result is less than satisfactory. 10. Expedite improvements. Many organizations take too long to implement major improvements and the efforts stall. Don’t assume that transformational improvements will take months or years to implement. Results can occur in a relatively short time if organizations enlist the help of their entire workforce, properly deploy effective resources, create meaningful metrics and focus on technology that will support the improvement effort. Don’t be unreasonable but challenge the current thinking and spend time “out of the box” for a new perspective. Think days or weeks, not years. Quality professionals are positioned to help their organizations focus on the vital few initiatives. The roadmap to success has been laid by Deming and Juran. Let’s be an integral part of the transformation and be the beacon to light the way. 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].

www.qualitymag.com

Your Comprehensive Resource for Quality Assurance and Control

Exhibition and Conference:

March 14–15, 2012

Sponsored by:

'PSU
8PSUI
$POWFOUJPO
$FOUFS
t
'PSU
8PSUI
59 t Meet face-to-face with top suppliers t See the newest products, materials, and equipment

BONUS! Quality Expo Texas joins the region’s premier advanced design and manufacturing event, featuring these co-located resources:

t Compare solutions side by side t Network with industry peers t Gain fresh ideas to improve product and business performance margins

For more information and to register, visit:

QualityExpoTexas.com Please use Promo Code: AB 1SPEVDFE
BOE
NBOBHFE
CZ
6#.
$BOPO
t
VCNDBOPODPN

OTHER DIMENSIONS

DOES NEW STUFF

HAVE TO BE CALIBRATED? CALIBRATION ENSURES THE NEW STUFF IS GOOD.

D

oes new stuff have to be calibrated? The short answer to the question is “yes,” so you don’t have to read further unless you want to know why. The technical term “new stuff ” refers to new, unused gages and instruments. The main question leads to another thought. If the stuff is new, it has to be good or suppliers wouldn’t ship it—would HILL COX they? This comment suggests that the supplier actually checked your stuff before shipping, which is not always the case. It also assumes that the reliability of this inspection is good, which is not always the case either. Many makers of gages and measuring instruments include a piece of paper with each item which claims the items have been inspected. But the value collapses when the same piece of paper says that if the buyer finds the instruments to be incorrect, the supplier’s liability is limited to repair or replacement of the defective item. If the stuff is new, Being linguistically it has to be good or suppliers challenged, I assume that if the items have wouldn’t ship it—would they? been calibrated by their “highly skilled technicians,’’ there won’t be anything wrong with them. But, alas, my assumption is incorrect. Too many people accept these bits of paper as if they were as good as a calibration report. The fact that they don’t cost the buyer anything indicates what they are worth. So the answer to our primary question is followed by another question: What is going on here anyway? The answer to that question is: Not what you’d think. In a perfect world, finished gages must pass final calibration by someone other than the person who made them. This provides independent confirmation that the gages meet specifications. In our world, this is becoming an exception rather than the rule it used to be. Cost cutting is the reason this important final check is being omitted by many gage makers. And, this is done to try and meet the never-ending demands for lower prices by those gage users who consider a gage as little more than another lump of steel. If the gage maker, or their sales agent, doesn’t provide this check, the gage user is left to discover mistakes or errors the hard way. When this occurs, price is no longer the overriding preoccupation of the buyer.

18

QUALITY | February 2012

Smart gage buyers get new gages checked by their own laboratory or a competent outside facility to avoid these problems, or they pay for a proper calibration report from the gage maker. Accounting 101 will explain that savings on the purchase price will be offset by the cost of “final” calibration, if accuracy is to be ensured. New measuring instruments are frequently used out of the box, usually with few problems, but when problems arise, they can be just as expensive as fixed limit gages. Setting masters supplied with the instrument often are found not to be as advertised, which can create mayhem for all. Since many instruments are made off-shore by unknown companies, you can never be certain what you’re getting, irrespective of what brand name they carry in this market. While some makers shouldn’t be in business, most problems arise because the maker is producing instruments to the standards of a different country, and the American importer either doesn’t know this or does but simply neglects to pass this information along. Often the foreign standard allows errors that are much higher than what the equivalent U.S. standard permits. There is nothing wrong with this, providing the buyer is aware of the situation. Usually they are not. Interchangeable anvils, rods and other devices may have settings that are incorrect and will never be found until the instruments are calibrated. Distributors may have mixed up these items from one set with those of another without realizing the implications of doing so. Similar problems arise with lever-type test indicators when contact points from one model are mixed up with those belonging to another model. While the electronics on popular instruments are of a high standard today, not all of them are. Occasionally intermittent defects occur and may cause a lot of rejects until they are found. The only way to avoid having these troublesome situations is to know that every gage or instrument entering your operations is good on the way in. And the only way to know that is to confirm it through calibration. Hill Cox president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

www.qualitymag.com

Your Gateway to the Education, Tools and Partnerships Needed to Turn Your Big Ideas into Market-Ready Products

An investment in your business, product, and you. Start the new year off strong with education, leading suppliers and resources you need to thrive in an environment that demands speed, quality, precision, and innovation.

Exposition: February

14–16, 2012 Conference: February 13–16, 2012 Anaheim Convention Center Anaheim, CA

For information on exhibiting or attending, please visit

MDMwest.com Please use Promo Code: AB

LEGAL INSIGHT

CHOOSING BETWEEN A

CORPORATION AND LLC MAKE AN INFORMED CHOICE.

S

uppose you operate a company with two lines of business—a service business such as Six Sigma consulting, and a manufacturing business such as precision instruments. They have different customers, growth prospects, reinvestment needs, returns on capital and cash flow characteristics. They face different types of risks. BRYAN L. In the 9th of his 14 points, W.E. Deming taught BERSON ESQ. managers to break down barriers among staff areas. In the example above, the units are distinct divisions in a conglomerate. For organizational and practical purposes, good management would separate them. In the event of a lawsuit, formal separation would prevent liability from spilling over into the other division. Management can determine which unit earns a higher rate of return on invested capital and which is the better choice for reinvestment. Perhaps, management will decide In the 9th of his 14 points, that one division should W.E. Deming taught managers be spun off. How can management to break down barriers achieve this artificial among staff areas. separation? Good legal structuring techniques and corporate governance can handle this. Most businesses choose between forming a corporation and a limited liability company (LLC). To make an informed choice, professionals require a basic understanding of the differences between the two types of entities. Corporations have been part of American business for centuries. They are chartered under state law and owned by shareholders. LLCs have been around only since 1977. They tend to be more flexible and have fewer formalities than corporations do. The owners of LLCs are called members. • Limited liability. Entrepreneurs form entities primarily to have limited liability. When people operate a business without an entity, they are sole proprietors. By forming a corporation or LLC and obeying the proper legal formalities, owners are relieved from personal responsibility for company debts and obligations. • Control. Corporations and LLCs differ with respect to how owners exercise control over their ownership interests. Corporate shareholders elect a board of directors that hires management. In large corporations, shareholders tend to be uninvolved in managerial decisions. In small closely held corporations, the same

20

QUALITY | February 2012

individuals tend to be shareholders, directors and managers. In LLCs, one or more members can manage the company, or they can hire an outside manager. • Transferability of interests. Very large companies tend to be structured as corporations. The structure enables them to more easily raise capital and transfer ownership interests. Unless the shareholders voluntarily contract to not sell or transfer their shares, they can do so, albeit securities laws may apply. With respect to LLCs, members can freely transfer the financial rights attributable to their shares. On the other hand, their rights to transfer managerial and voting rights are usually restricted. State law and operating agreements often require remaining members to consent for an assignee or purchaser to become a full member. • Continuity. Corporations and LLCs exist in perpetuity. They survive the bankruptcy, retirement and deaths of their owners. Sole proprietorships die with the owner. • Taxation. Most entity choice decisions are driven largely by tax considerations. Thus, before choosing an entity, an entrepreneur or manager should consult with an accountant or tax professional who has experience with small businesses. Regular corporations (C corporations) are separate legal entities. They file tax returns and pay taxes. Dividends paid to shareholders are taxed as well. This “double taxation” can be avoided if the corporation is eligible and elects to be taxed as an S corporation. An S corporation is a “pass-through entity.” It files informational returns with tax authorities but does not pay taxes. Rather, its shareholders report the profit or loss on their personal tax returns. Some corporations are ineligible to be S corporations. Sometimes, it does not make practical sense to become one and deal with the legal restrictions. LLCs, like S corporations and partnerships, also are pass-through entities. Where the member is an individual, he is taxed like a sole proprietor. Where the member is a corporate owner, the LLC is treated like a division of the parent company. Disclaimer: This column is for informational purposes and does not constitute legal advice.  Bryan L. Berson, Esq. is an attorney, mediator and the president of The Berson Firm, P.C., a commercial and civil law firm specializing in business law, real estate, mediation and litigation. He may be reached at bberson@bersonfirm.com.

www.qualitymag.com

READY TO RESHAPE YOUR FUTURE

REGISTER NOW AT NPE.ORG

From more large-scale, running machines than ever before to solutions that cover the entire plastics industry lifecycle, the advancements that deliver a competitive advantage can only be found this April at NPE2012, the world’s largest plastics conference, exposition and technology exchange. Join your peers in Orlando to Break the Mold — and reshape the paradigms that will lead to a more successful future. Showcasing innovations from more than 2,000 globally focused exhibitors, NPE features: 2+ million square feet of tomorrow’s solutions, today More large-scale, running machines in action Interaction with 75,000 industry peers from more than 120 countries Access to hundreds of timely educational programs and daily emerging technology demos And much, much more! Don’t wait — connect with the entire lifecycle of plastics this year and uncover the solutions needed to move your company, products and career forward.

ATTEND NPE2012!

Co-located at NPE2012:

The International Plastics Showcase April 1– 5, 2012 | www.npe.org Orange County Convention Center Orlando, Florida USA

GD&T WORKSHOP

THE PERFECT

IMAGINARY WORLD OF GD&T Discover the important components of the perfect imaginary world of GD&T. BY BILL TANDLER

L

et’s start with a definition. Geometric dimensioning and tolerancing (GD&T) is a symbolic language with which to manage imperfect geometry perfectly, that is, with which to impose fault tolerant, permissible limits of imperfection, which guarantee the assembly and operation of manufactured parts and keep costs down. In order to manage imperfect geometry perfectly, we need a set of perfect tools and a perfect language beholden to perfect rules with which to implement them. The most important components of the perfect imaginary world of GD&T are tolerance zones, tolerance values, datums, datum reference frames, basic dimensions and a symbolic language.

1

Tolerance zones. Tolerance zones are perfect, imaginary bounded regions of space within which a particular feature component is required to lie. As shown in Figure 1, tolerance zones come in many shapes, of which

Tolerance Zone Shape: tube-like

the most important are cylindrical, tube-like, slab-like and skin-like. Cylindrical zones, for example, as defined by the position tool, normally serve to constrain the orientation and location of a perfectly straight axis, but also can constrain the straightness of a potentially bent median line. Tube-like zones can set upper and lower limits on the size as well as the form of a bore using the diameter or the surface profile tool. If we impose a constant wall thickness but allow a tube-like zone to expand and contract in order to accommodate changes in the size of a bore, it serves only to constrain its form, namely its cylindricity. Slab-like zones, on the other hand, can be used to limit the flatness and the orientation and the location of a planar surface using the surface profile tool, or can serve to orient and locate the midplane of a slot using the position tool. Finally, compound curved skin-like zones defined by the surface profile tool, can control the size, form, orientation and

Tolerance Zone Shape: cylindrical

Tolerance Value: wall thickness

Tolerance Value: diameter

Tolerance Zone Shape: skin-like

Tolerance Zone Shape: slab-like

Tolerance Value: width

Figure 1: Tolerance Zones and Tolerance Values

Figure 2: Datums

22

QUALITY | February 2012

Tolerance Value skin thickness

location of compound curved surfaces, such as an automobile fender. Tolerance zones are form-perfect by definition.

2

Tolerance values. The next most important component of the perfect imaginary world of GD&T is the tolerance value, which specifies the size of a tolerance zone. As shown in Figure 1, in the case of the cylindrical zone, the tolerance value defines its diameter. In the case of the tube-like zone, the tolerance value defines the wall thickness; in the case of the slab-like zone, the thickness of the slab; and in the case of the skin-like zone, the thickness of the skin. Just like tolerance zones, tolerance values are also perfect.

3

Datums. By merely defining the size and form of a skin-like tolerance zone, we can control the size and form of a feature. But if we could also orient and locate the zone, we could control the feature’s orientation and location as well. We always control the orientations and location of geometric entities using a coordinate system, but the question then arises, what coordinate system? Thus, coordinate systems have to be established, and the tools for doing so are called datums, namely the perfect, imaginary reference points, lines and planes we extract from the datum features of a machine part. Figure 2 illustrates the six alternative datums we will need, namely a stand-alone point, line or plane, a point-on-a-line, a line-in-a-plane and a point-on-a-linein-a-plane, each of which constrains a different set of degrees of freedom.

4

Coordinate systems. Coordinate systems consist of three perfectly straight, mutually perpendicular axes [x], [y] and [z], which intersect to create an origin [xyz], and which act in pairs to form three perfectly flat, mutually perpendicular base-planes [xy], [yz] and [zx]. With a set of datums in hand, we can constrain the six degrees of freedom of a coordinate system—namely pitch, yaw, roll and translation in x, y and z. By outfitting the axes with linear scales, we can provide a complete frame of reference with which to orient and locate tolerance zones. Because they are established using datums, said coordinate systems are referred to as datum reference frames. (See Figure 3.)

www.qualitymag.com

5

Basic dimensions. After we have established a datum reference frame, we need a way to orient and locate tolerance zones relative to them. In order to clearly differentiate between the toleranced nominal dimensions we use for size control, and the fixed dimensions we reserve for orienting and locating tolerance zones, we place the latter inside rectangular frames and refer to them as “basic.” In Figure 4, we see a cylindrical tolerance zone which has been oriented by the implied basic angle of 90 degrees relative to the XY base plane, and located by the explicit basic linear dimensions of 50 and 70 millimeters relative to the X and Y axes of the datum reference frame established using datums A, B and C.

Z Y

Figure 3: Datum Reference Frames

Z[A,B,C] Y[A,B,C]

70

50

Bill Tandler is the president and chief technical officer of Multi Metrics Inc. (Menlo Park, CA). He can be reached at GDandTWorkshop@ qualitymag.com or (650) 328-0200.

www.qualitymag.com

X[A,B,C]

Basic Dimensions

Figure 4: Basic Dimensions

Diameter Tool Position Tool Cylindricity Tool

Feature Control Frames

Figure 5: The Symbolic Language of GD&T

0

45

In the end, GD&T is very simply a set of symbolic tools with which to define coordinate systems in real objects and with which to specify the shape, size, orientation and location of tolerance zones. Figure 6 illustrates a partially GD&T encoded drawing and the tolerance zone forest defined by the indicated feature control frames. Editor’s Note: Visit www.qualitymag. com (keyword: GD&T Workshop) to view the explanation for the first of the three drawings in the January GD&T Workshop. Comments on the remaining two drawings will follow once we have an adequate GD&T foundation.

An oriented and located Tolerance Zone

A Datum Reference Frame

6

Symbolic language. Finally, in order to impose the perfect imaginary world of GD&T on imperfect real parts, we need a way to express and communicate our requirements. This is done with the symbolic language consisting of rectangular feature control frames which we stuff with geometry control tool icons like those for position and cylindricity, followed by tolerance zone shape modifiers such as the Ø symbol, followed by tolerance values, followed by tolerance zone size modifiers, namely the symbols (S), (M) and (L) associated with said tolerance values, followed by datum feature labels, namely A, B and C, finally followed by tolerance zone mobility modifiers, namely the symbols (S), (M) and (L) associated with said labels, all shown in Figure 5.

X

45

Primary GD&T Functions A

(1) Coordinate System Establishment

0 18

25 50

C

B

(2) Tolerance Zone shape, size, orientation and location Specification

Z axis of DRF [A,B,C] X axis of DRF [A,B,C]

Y axis of DRF [A,B,C]

Planar Datum Feature A

Axis of Datum Feature B

Planar Datum Feature C

Figure 6: A Tolerance Zone Forest

February 2012 | QUALITY

23

QUALITY 101  While large floor-standing machines with very large screens and manual axis control provided the best accuracy 25 years ago, improved optics, readout devices, backlighting, software/ computation systems and precisely controlled motorized work-stage travel combine to provide sophisticated, compact platforms. Source: Starrett

compact platforms. Projectors are available as benchtop machines or floorstanding models in either horizontal or vertical orientation with screen sizes ranging from 12 inches to 40 inches. 

21ST CENTURY

OPTICAL COMPARATORS New technologies adapted to optical comparators have given this time-tested measuring method new life, making it a versatile, cost-effective alternative for many noncontact measurement applications. BY MARK G. ARENAL

O

ptical comparators have steadily evolved from the simple comparative shadowgraph devices of 60 years ago to the more complex, precision optical measuring systems of today. Some had predicted they would be replaced by other technologies such as camera-based (video) measuring systems. However, they continue to play an important role in noncontact measurement of profile dimensions. They also are practical alternative to video

24

QUALITY | February 2012

technology for many applications. In addition, there is a large installed base of optical systems so many people are already trained in their use. While large floor-standing machines with very large screens and manual axis control provided the best accuracy 25 years ago, improved optics, readout devices, backlighting, software/ computation systems and precisely controlled motorized work-stage travel combine to provide sophisticated,

ADVANCED SOFTWARE AND READOUTS Today’s machines are markedly different from the first shadowgraphs that could only compare projected images of the work piece to overlays for simple pass/ fail inspections. While today’s projectors can still be used for overlay or comparative purposes, an ever-increasing demand ffor quantitative data has given rise to advanced optical comparators with a wide a rrange of software and readout systems.  Readouts today vary in sophistication ffrom traditional micrometer heads or iindicators to digital readouts, microproccessor displays with geometric measurement capabilities and PC-based systems. m IIn addition, an edge-detection capabiliity, which allows the system to automatically detect and measure transition m points of a profile image, has become p a common industry feature. The combined effect of these capabilities has b eessentially transformed optical projectors from comparative tools to two-axis coordinate measuring machines. Other automated features further enhance the capabilities of comparators. An operator may select a machine with manual, motorized or fully automatic operation. Fully automatic or computer numerical control (CNC) machines fitted with motors and edge-detection, allow part inspection to be completed under CNC control. Readout systems of today also are flexible because they allow for software expansion, as programs continue to add enhancements.  Super fast geometric processors make it possible for some projector software to interface to computer-aided design (CAD) to simplify part programming. This capability, combined with CNC control, allows features to be measured

www.qualitymag.com

and constructed automatically with the results displayed on-screen or documented through various reporting options.  QUANTITATIVE DATA To get an idea of how much data today’s comparator can extract, consider the results that can be determined by measuring the diameter of a circle: • the maximum or minimum diameter.  • the average diameter based on all measurement points taken, or the mean diameter based on the high and low values (ISO).  • form (out-of-roundness) shown simply on a graphical display.  • tolerances also can be applied to features, be they Cartesian, true position, maximum material condition (MMC) or least material condition (LMC).  UNIQUE ENHANCEMENTS Incremental improvements based on new and emerging technologies continue to extend the utility of 21st century comparators. Here are two examples: • Optical-video adapter. This technology allows optical comparators to be converted into a basic two-axis manual video measuring systems by simply interchanging the comparator lens with a camera-based, video zoom package. The optical-to-video adapter utilizes the same quick-change bayonet mount that an operator would use to change from a 10X lens to a 50X lens, with no tools required. It allows operators to obtain excellent surface illumination at substantially higher magnifications than would normally be possible with comparators. • Touch-screen control. A new readout technology, analogous in function to tablet computers, provides a broad range of powerful, easy-to-use comparator functions via a compact, icon-based touchscreen interface. They provide instant information on feature form, tolerances and measurement data; coordinate display for X and Y axes and Q radius values for screen rotation and allow for easy part alignment and datum functions at the touch of a finger.

While today’s projectors can still be used for overlay or comparative purposes, an everincreasing demand for quantitative data has given rise to advanced optical comparators with a wide range of software and readout systems. Source: Starrett

lighting and high-resolution optics. When selecting a system, it pays to focus on these critical basics, being careful to evaluate each element of the system. That being said, modern optical projectors continue to be noncontact measurement workhorses because of

their exceptional practicality, durability versatility, and ease of use. Mark G. Arenal is general manager of the Starrett Metrology Division (Laguna Hills, CA). For more information, call (949) 348-1213, e-mail [email protected] or visit www.starrett.com.

SOME THINGS NEVER CHANGE Regardless of how advanced a readout system is or how powerful the software, optical equipment will not perform to desirable standards without a high quality, stable machine platform, superb

www.qualitymag.com

February 2012 | QUALITY

25

INNOVATIONS  QI Macros is software designed for manufacturing companies to control chart templates and provide real-time charting from gages on the production line. Source: KnowWare International Inc.

QI MACROS FOCUS ON

“VITAL FEW” TOOLS Software boasts tools designed to solve 99% of typical business problems. BY DARRYL SELAND, EDITOR IN CHIEF

K

are four wizards to simplify analysis: nowWare International Inc.’s Statistics, PivotTable, Control Chart (Denver) QI Macros is software and Chart.” designed for manufacturing compaAccording to Arthur, QI Macros nies to control chart templates and focuses on tools that will solve 99% of provide real-time charting from gages typical business problems. on the production line. Hypothesis “There is a ‘long tail’ of statistical testing tools such as ANOVA, t Test, tools that are rarely used,” Levene’s test and others says Arthur. “A statistiare part of the package. SPECIFICATIONS cian might occasionThe software works in » Available in both PC and ally require more exotic Microsoft Excel 2000Macintosh formats tools like Attribute 2011 in both PC and » Runs in Windows XP, Agreement AnalyMacintosh formats and, Vista or Windows 7 sis. The QI Macros focus according to the com» Requires Excel or Office on the ‘vital few’ tools, pany, is the only product 2000, XP, 2003, 2007 or not the ‘trivial many,’ as that supports Macintosh. 2010 (Macintosh Excel Juran would say.” “It’s so easy to use that 2001, 2004 or 2011) QI Macros has a Pivotpeople don’t need much » Works in all international Table Wizard to analyze training to get started,” versions of Excel rows of text data and consays Jay Arthur, creator » Uses 8 MB storage vert it into measurements of QI Macros. “There

26

QUALITY | February 2012

that can be charted. There are many control chart macros and fill-in-theblank templates. “Some people try to create their own control chart templates, but use incorrect formulas and wonder why the QI Macros deliver different, more challenging results,” says Arthur.  What makes QI Macros innovative, says Arthur, is that, unlike most statistical process control (SPC) packages that ask users to first select a chart and then select the data, QI Macros asks users to first select the data and then choose a chart. The advantage is that QI Macros can look at the data (integer or decimal, single- or multi-column) and decide what chart or statistic to use. “The Chart, Control Chart and Statistics Wizards make it easy for a user to get the right answer,” says Arthur. “Where [other software] asks users to navigate a decision tree in the Quality Advisor to choose a chart or statistic, the decision tree is built in to the QI Macros and does the work for you.” The software also contains fill-inthe-blank control chart dashboards that can handle hundreds of metrics. THE IDEA OF QI MACROS According to Arthur, when he left the phone company in 1996 after five years in total quality management, he knew he needed easy-to-use tools. As a quality professional and computer programmer, he noticed that Windows 95 and Excel 5.0 had a macro programming capability, so he started developing the tools for his own use. “When I discovered how easy it could be to draw a pareto chart, histogram or control chart using Excel and macros, I put together a prototype and started offering it through direct mail to members of the American Society for Quality [ASQ],” he says. Arthur called the software QI Macros because it was for quality improvement [QI] and used Excel’s macro language [Macros]. “Through endless feedback and improvement over the last 15 years, the QI Macros have evolved into a rich

www.qualitymag.com

environment for performance improvement and sustaining improvements,” Arthur says. Today, there are more than 100,000 users in 80 countries in industries as diverse as healthcare, hotels, manufacturing (especially auto), transportation, power and aerospace. In

Any Gage

The software also contains fill-in-the-blank control chart dashboards that can handle hundreds of metrics. Source: KnowWare International Inc.

particular, the software is used to improve quality processes and procedures at Boeing, Florida Power & Light and Kaiser Permanente. The Veterans Administration uses the software to improve quality and cost of care for veterans in hospitals and medical centers.

For more information, contact: KnowWare International Inc. 2253 S. Oneida Street, Ste. 3D Denver, CO 80224 (888) 468-1537 www.qimacros.com

Why Risk Performance? High Performance demands Production Efficiency and Proactive Solutions ‡9HULI\*R 1R*R'LDPHWHUV ‡3URYLGH$XGLWDEOH5HDGLQJV ‡9HULI\([DFW0DWLQJDQG,QWHUFKDQJHDELOLW\RI7KUHDGV ‡1R([SHQVLYH7KUHDG6HWWLQJ0DVWHUV5HTXLUHG ‡0HDVXUH0XOWLSOH6L]HVZLWK21(*DJH ‡0HHW$16,$60( ,626SHFLILFDWLRQV

Measure a Variety of Thread Forms & Sizes

4XDOLW\7KUHDG*DXJLQJ(TXLSPHQW

VERSATILITY

An example of a pareto chart created using QI macros. Source: KnowWare International Inc.

‡JDJHPDNHU#JDJHPDNHUFRP

www.gagemaker.com www.qualitymag.com

February 2012 | QUALITY

27

MEASUREMENT

The

Democratization of Measurement

Smaller and more affordable 3-D measurement technology is changing the job descriptions of level 1 operators. BY GREG RICHARDS

C

Times change, though, and with ompared with the modern wizardry them, entire strata of operators and that goes on every users have been elimiday in homes and offices TECH TIPS nated from operations across America, indus» Quality assurance is now throughout the United trial technology can seem in the hands of employees States. For many, the pretty mundane. When who may have never operjob of quality assurwas the last time you were ated a CMM before. ance and inspection has excited—really excited— » New measurement arms been passed down to about a new lathe? allow for 3-D contact and the level one operator Generally, time on noncontact measurement of who typically was not the shop or factory floor parts and machines, often charged with matters means abandoning the without so much as a lapof advanced metrology. creature comforts such top connection. Manufacturers of coordias the Internet, Wi-Fi, » To facilitate these meanate measuring machines touch screens and so on. surements, portable CMM (CMMs) are recognizing The really cool stuff, manufacturers now incorpothis shift and designing we’re told, was for the rate familiar features into their arm. products that are simguys upstairs.

28

QUALITY | February 2012

pler and faster to use, and work more like the smart phones that sit in your pocket rather than the multi-ton, fixed bridge CMMs of the past. THE GREAT METROLOGY MIGRATION To understand this shift, one must first understand the driving force behind it. It is no secret that the manufacturing industry has seen nearly three million jobs eliminated the past five years or so, according to the Bureau of Labor Statistics. While many of these jobs were lost on the shop floor, many others were entire tiers of jobs charged with advanced operations such as metrology. Many auto manufacturers, for example, no longer hire experienced metrologists to perform their daily quality assurance and part measurement operations. Instead, they employ only a few to resolve high-level threats to quality.

www.qualitymag.com

Simple measurement functions do not cease simply because the hiring does. Circularity, perpendicularity, parallelism, diameter, width—these do not stop going out-of-whack because a manufacturer no longer employs dozens of trained measurement experts. Simply, quality remains a concern regardless of economic conditions. The duties of quality assurance have now been pushed down the ladder to the shop floor. On-machine and on-party inspections are commonplace in metal fabrication, automotive facilities and factories throughout the United States. WHY THE MOVE TO 3-D? Quality assurance is now in the hands of employees who perhaps have never operated a CMM before. Device manufacturers know this. So, to accommodate the shift from scientists to assemblers, portable CMM manufacturers are making their devices more user-friendly than ever. New measurement arms allow for 3-D contact and noncontact measurement of parts and machines, often without

Times change and with them entire strata of operators and users have been eliminated from operations throughout the United States. For many, the job of quality assurance and inspection has been passed down to the level one operator who typically was not charged with matters of advanced metrology. Source: Faro

so much as a laptop connection. In fact, the move to 3-D data capture has allowed for simplified measurements of very complicated dimensions—such

as circularity—by workers who might not have had previous experience with such things. To facilitate these measurements, portable CMM manufacturers now incorporate familiar features into their arm. Features include a touch screen, much like one would find on any of today’s smart phones, which provides a simple interface to routine measurement functions (think depth, distance, diameter, etc.) without a laptop connection. Sphere, square and line icons distinguish between the functions to clarify their purpose and remove any doubt over the feature being measured. Newer arms offer Wi-Fi, BlueTooth and other connectivity options to enable measurements at the part, rather than bringing the part to the CMM. Measurement reporting is another area that has seen rapid change. As software evolves to conform to the new needs of manufacturers, so too does the results reporting that is generated by their efforts. In the past, measurement routines were included in complicated reports that showed part dimensions as

the infinite

possibilities

of process control

Eliminate measurement constraints with the new infinite positioning PH20 CMM touch trigger system. Using technologies developed for the multi-award winning REVO®, the new compact PH20 from Renishaw changes CMM touch-trigger probing forever, with fast, infinite, 5-axis positioning.

PH20 reduces the effect of CMM dynamic errors by only moving the probe head and eliminating indexing for a 3-fold increase in throughput. See the new PH20 in action: Renishaw.com/PH20

Renishaw Inc. Hoffman Estates, IL www.renishaw.com

www.qualitymag.com QLT10114Reni.indd 1

February 2012 | QUALITY 9/14/11

29 AM 9:53

MEASUREMENT

Quality assurance is now in the hands of employees who perhaps have never operated a CMM before. Device manufacturers know this. So, to accommodate the shift from scientists to assemblers, portable CMM manufacturers are making their devices more user-friendly than ever before. Source: Faro

Power & Value You Can See

Jet Engine Turbine Blades

complex numbers and measurements. Now, software packages that work with arms are equipped with advanced part-to-CAD report generation. These documents provide the operator with easy-to-understand deviations from computer-aided design (CAD), allowing for quick adjustment to manufacturing processes. Newer measurement arms offer better weight balancing, sometimes as much as 25% less strain on the operator, to reduce fatigue for the line worker who now may be required to make dozens of point measurements at a time. The incorporation of consumer technologies—touch screens, Wi-Fi and quick reporting—with industrial equipment makes measurement less daunting for the level one operator, and for some, makes the need to employ advanced metrologists a thing of the past. By simplifying the technology of measurement though, the impact is not as great as one would expect. Today, data is simpler and quicker to understand and presents inspection results in a user-friendly format. The

PRODUCTION GAGING SOLUTIONS Custom Medical Taper Gages Micro II Two Channel, Three Display air gage readout for fast and reliable inspection of internal and external taper in products such as

tapers.

Experience the NEW AbrasiMet® 250 Abrasive Cutter

Western Gage Corporation

®

Solutions for Materials Preparation, Testing and Analysis

Excellent Results. Easily Repeatable.™

30

QUALITY | February 2012

www.buehler.com

Camarillo, CA Ph 805 4451410 FAX 805 4457530 Email: [email protected] Web Site: westerngage.com Supplying dimensional air gages to assure the quality of precision parts since 1968. www.qualitymag.com

The migration of measurement functions from the few to the many means that more parts can be measured off the line and closer to the point of manufacture than ever before. The elimination of high-level manufacturing technicians has reduced payroll and increased margins for employers, particularly as the cost for their quality assurance technologies has dropped. Source: Faro

migration of measurement functions from the few to the many means that more parts can be measured off the line and closer to the point of manufacture than ever before. The elimination of high-level manufacturing technicians has reduced payroll and increased margins for employers, particularly as the cost for their quality assurance technologies has dropped. As the size, complexity and cost of consumer electronics are reduced, we can expect to see similar reductions in the industrial sector. As this migration occurs, expect to see functions, such as metrology, that had been reserved for very experienced operators pushed further to lower tiers of the operation. It is this sort of democratization that has led manufacturers to compete variable costs for years. Quality assurance, it seems, is the next battleground. Q Greg Richards works at Faro Technologies Inc. (Lake Mary, FL). For more information, call (800) 736-0234, e-mail [email protected] or visit www.faro.com.

QUALITY ONLINE For more information on 3-D measurement, visit www.qualitymag.com to read the following: • “3-D Measurement Hits the Road” • “Back to Basics with 3-D Optical Measurement” • “Portable CMMs Go to Source of Inspection”

www.qualitymag.com

February 2012 | QUALITY

31

TEST & INSPECTION

Sensing the Thread Inductive displacement sensor technology is used for thread detection. BY DAN SPOHN

T

have current induced at its surface. here are numerous methods to check This eddy current, in turn, produces its thread quality, but in many instances own oscillating electromagnetic field. it is not thread quality that is the paraThe interaction between the coil field mount concern. What keeps quality and eddy current field varies with the engineers and manufacturing engineers distance between the coil (probe) and responsible for high-volume producthe sensed material surface (target). The tion lines up at night is the probe electronics senses the potential disaster of shipTECH TIPS varying interaction and ping parts that have not » Inductive technology will produces an analog voltbeen threaded at all. see through oil, grease age proportional to the and grime, so a go/no-go probe-target gap. BACKGROUND check for threads presence The portion of the field Inductive eddy current can occur in the producradiating axially from the technology has been used tion line, close to the probe is what is used in for linear displacement threading operation. displacement sensing. sensing for more than 50 » Probe diameter will affect the For thread detection, years. With inductive dissensing range, so one probe the radial portion of the placement sensors a wiredoes not sense all threads. field is used. When a wound coil housed in a » In addition to presence, probe is inserted into a probe is excited with high inductive sensors also can be drilled hole, the analog frequency AC, typically used to detect thread depth. output voltage will indi500 KHz or 1 MHz. The cate the gap between the coil produces an oscillatoutside diameter of the ing electromagnetic field probe and the inside diameter of the around the probe tip. Any electrically drilled hole. Because the eddy current conductive material that engages the induced in the surface only penetrates oscillating electromagnetic field will

Target

Oscillating electro-magnetic field

Probe

Eddy current Eddy current field

The eddy current produces its own oscillating electromagnetic field. The interaction between the coil field and eddy current field varies with the distance between the coil (probe) and the sensed material surface (target). The probe electronics senses the varying interaction and produces an analog voltage proportional to the probe-target gap. Source: Kaman Precision Products

32

QUALITY | February 2012

a few thousands of an inch, when the probe is inserted into a tapped hole, the eddy current follows the contour of the threads. In tapped holes, the analog output indicates the gap between the probe outside diameter and what is essentially the pitch diameter of the threads. TECHNOLOGIES Optical and laser based displacement sensing technologies can and have been used for thread detection. Optical sensors rely on the presence of a thread to reflect the sent beam back to a receiver, similar to how they are used in displacement sensing. If the hole is not threaded, then there is no reflectance of the sent beam. It looks to the sensor like the target is out of range. Inductive sensing technology offers some advantages over optical and laser sensing. • Inductive technology will see through oil, grease and grime, so a go/no-go check for threads presence can occur in the production line, close to the threading operation. This eliminates a bad part from incurring further costs from downstream operations. • Because it in unaffected by cutting fluids, oil mist and vapor, performance will not degrade over time from condensation collection on optical lenses. • With the probe connected to the electronics via the small coax cable, the electronics can be remotely located in a suitable environment on the production floor. This also allows for very small probes to be used. Inductive thread detection does have some application requirements. • Probe diameter will affect the sensing range, so one probe does not sense all threads. As the thread diameter increases so must the probe diameter. • The probe must be inserted into the threaded hole—or in the case of external threads, over the stud. The depth

www.qualitymag.com

easy • accurate • automatic

Break Edge and Radius Inspection

Indicates thread pitch diameter

Indicates tap drill diameter

LVDT indicates sensor depth at thread/hole interface

When a probe is inserted into a drilled hole, the analog output voltage will indicate the gap between the outside diameter of the probe, and the inside diameter of the drilled hole. Because the eddy current induced in the surface only penetrates a few thousands of an inch, when the probe is inserted into a tapped hole, the eddy current follows the contour of the threads. In tapped holes, the analog output indicates the gap between the probe outside diameter, and what is essentially the pitch diameter of the threads. Source: Kaman Precision Products

In addition to presence, inductive sensors can also be used to detect thread depth. Adding a long range displacement sensor such as an LVDT to the insertion mechanism provides insertion depth feedback. By monitoring the analog output of the inductive sensor as it is being inserted, it is possible to detect the analog voltage decrease when the probe coil passes from the last of the threads to the start of the tap drill diameter. Source: Kaman Precision Products

is not critical per se, but the repeatability of insertion depth is. This is particularly a concern when detecting thread presence in thin plate material. The insertion depth repeatability can be controlled with the design of the insertion mechanism. • The radial location of the probe in the threaded hole is similar to axial location in that it is not necessarily critical where it is, but it is critical that the probe be in the same radial location for each part being checked. As with axial insertion, radial insertion repeatability tolerance is easily controlled with the design of the insertion mechanism. • Damage to a probe is certainly a possibility with automated checking, from a broken tap to a misaligned part. Incorporating a spring-loaded probe mount in the design of the insertion mechanism will greatly reduce probe damage potential.

displacement transducer (LVDT) to the insertion mechanism provides insertion depth feedback. By monitoring the analog output of the inductive sensor as it is being inserted, it is possible to detect the analog voltage decrease when the probe coil passes from the last of the threads to the start of the tap drill diameter.

In addition to presence, inductive sensors also can be used to detect thread depth. Adding a long range displacement sensor such as an linear variable

www.qualitymag.com

AVOID CONFUSION Not to be confused with inductive proximity sensors, inductive displacement sensors are very sensitive to small changes in gap between the probe and the target. Sensitivities of 100 millivolts/mil are commercially available as standard catalog items. It is this high sensitivity that allows reliable thread presence detection in both coarse and fine pitch threads, and roll formed threads, in both ferrous and nonferrous metals. Q Dan Spohn is an applications engineer at Kaman Precision Products/Measuring, a Division of Kaman Aerospace Corp. (Colorado Springs, CO). For more information, call (719) 635-6957, e-mail [email protected] or visit www.kamansensors.com.

Dual-Stripe Handheld USB Sensor

• Designed for limited access areas • Operator feedback for optimum positioning • Algorithm corrects for pitch and yaw misalignment • High resolution scan, accuracy to within ± 0.0005-inch • USB connection to laptop, tablet or to LaserGauge LG1200 controller

Measure: Edge Radius, Break Angle, Arc Angle, Blend Distance, Surface Angle

www.origintech.com 256-461-1313 February 2012 | QUALITY

33

SOFTWARE & ANALYSIS

Good Data =

Good Decisions Measurement system analysis helps to judge whether an attribute gage is trustworthy. BY WILLIAM D. KAPPELE AND JOHN D. RAFFALDI

G

variability due to different operators ood data are necessary for good using the gage differently. Repeatability decisions. Good data come from and reproducibility together are called measurements that are gage repeatability and as free from variation as TECH TIPS reproducibility (GR&R). possible, also known as » Measurement system analyWhen you have a gage noise, and are accurate, sis helps to judge whether an that simply determines representing the true attribute gage is trustworthy whether a part is in value. Measurement sysmeeting inspection needs. specification (pass) or out tem analysis helps deter» Good data come from meaof specification (fail), the mine if a measurement surements that are as free sources of measurement system is free enough from variation as possible error are broken down from noise to make good, and are accurate. differently. There are still accurate measurements— » By performing GR&R studthree categories to look an essential step in proies before introducing at: percent effectiveness, ducing good data. any gage to production percent miss rate and For a typical measureor inspection, we can be percent false alarm rate. ment system analysis, the assured that our decisions The first, percent sources of measurement are based on good data. effectiveness, measures variability are broken into how well a measurement three categories: partsystem can identify parts to-part, repeatability and correctly as in or out of specification. reproducibility. The remaining two, percent miss rate Repeatability is the variability due and percent false alarm rate, identify to the gage itself. Reproducibility is the

how often specific errors are likely to be made. Percent miss rate measures how often an operator can “miss” an out of specification part, sending it out to customers. Percent false alarm rate measures how often an operator can raise a false alarm, or misidentify good product as out of specification. A pass-fail gage is called an attribute gage. As in a typical GR&R study, attribute gage studies use multiple operators who repeat measurements on the same part several times. Unlike a typical study, however, the measurements are either “pass” or “fail.” All of the precautions of a typical study such as randomization and blinding should be observed. EXAMPLE Let’s take a look at an example to understand an attributes GR&R study. The background to understand the data is as follows: Acme Gasket produces gaskets for the chemical industry. These gaskets must be at least 0.450 millimeter thick, but cannot be thicker than 0.545 millimeter. Thus, any gasket with a thickness between 0.450 millimeter

Partial Data for Gasket Attribute Study

Effectiveness Report for the Gasket Data

Source: JMP, a Division of SAS

Source: JMP, a Division of SAS

34

QUALITY | February 2012

www.qualitymag.com

Partial Data: Misses

Effectiveness Report After Correcting the Gage

Source: JMP, a Division of SAS

Source: JMP, a Division of SAS

and 0.545 millimeter will pass, while gaskets with thicknesses outside this range will fail. The test is performed by first passing the 25-millimeter wide gasket through a slit 0.545 millimeter high and 200 millimeter wide in an aluminum plate. If the part passes through, it is not too thick. Next the operator attempts to pass the gasket through a slit 0.450-millimeter high and 200-millimeter wide in another aluminum plate. If the gasket passes through this slit, the part is too thin. So, in order to pass, a part must pass through the first slit and fail to pass through the second. A portion of the data table is shown in the table, “Partial Data for Gasket Attribute Study.” Here is how to read the data table: • Part. Part identifier for the actual gasket being measured. • Standard. Whether the part passes (1) or fails (0) based on an independent measurement system of higher quality. (See RefValue below.) • Code. A “+” indicates all measurement of this part correctly identified it as in specification. A “-” indicates that all measurements correctly identified this part as out of specification. An x indicates that some measurements of this part were incorrect. • A, B and C. Pass (1) and fail (0) measurements for each of the operators. • RefValue. The thickness of the gasket as measured by a higher quality gage. The complete data table includes measurements for 50 gaskets measured three times each by each of the three operators. A partial report for the analysis of the gasket data is shown in

www.qualitymag.com

the table, “Effectiveness Report for the Gasket Data.” Notice that the overall percent effectiveness is about 94%. The percent miss rate (misses) is 6.25% for operators A and B, and 12.5% for operator C. The percent false alarm rate (false alarms) is 4.9% for operator A, 1.96% for operator

taper using the previous inspection method. A new attribute gage study was performed and the results are shown in the table, “Effectiveness Report After Correcting the Gage.” Notice that the now overall percent effectiveness is about 97.6%. The percent miss rate (misses) is 0% for operator A,

Guidelines for Evaluation

CHARACTERISTIC Percent effectiveness Percent miss rate Percent false alarm

GOOD >90% 23,000x. This ensures best possible quality of defect informa-tion in the vertical direction.

Microfocus X-Ray Inspection System

Skidless Surface Evaluation System Mahr Federal’s MarSurf® M 400 mobile surface metrology system features proprietary motorized probe height adjustment that quickly and automatically zeros the probe in seconds and can cut meas-urement time in half. The M 400 also features a magnetic, breakaway probe mounting system that pro-tects sensitive probes from accidental damage and facilitates fast probe changes. The MarSurf M 400 measures all common international parameters, and features Bluetooth

Advertiser American Society For Nondestructive Testing ANDEC Applied Test Systems Inc. Bruker Elemental Carestream Health Carl Zeiss Creaform Gradient Lens Corp. Instrument Technology Inc. Machida Olympus NDT Proceq USA, Inc. Scienscope International Spectronics Corp. Sun-Tec Corp. Test Equipment Distributor TUV Rheinland Industrial Solutions Varian/BIR Verimation Technology Yxlon International

The new phoenix x|aminer from GE’s Inspection Technologies business is a 5-axis, microfocus X-ray inspection system, which has been developed for quality control applications in the manufacture of electronics sub-assemblies. The phoenix x|aminer features two megapixel high resolution, high magni-fication and its powerful imaging software permits intuitive programming and component manipulation is precise and easy using a computer mouse or joystick. An important design feature of the new

Page

Phone

29NDT 19, 30NDT 17NDT 35NDT IFCNDT 33NDT 18NDT 16, 22NDT 31NDT 17NDT 3, IBCNDT 21, 23NDT 34NDT 1NDT 23NDT 26NDT 25, 27NDT 9NDT 20NDT BCNDT

(800) 222-2768 (416) 213-8000 (724) 283-1212 (800) 366-9956 (800) 327-9735 (302) 444-6696 (800) 536-0790 (413) 362-3606 (845) 365-0600 (800) 225-8330 (724) 512-0330 (800) 216-1800 (800) 274-8888 (248) 669-3100 (800) 962-1788 (800) 748-0208 (702) 938-4859 (800) 521-5245 (330) 798-4834

GE Sensing & Inspection Technologies GmbH (49) 5031 172-0 [email protected] www.ge.com

Web Address www.asnt.org www.andec.ca www.atspa.com www.bruker.com/hhxrf.com www.ndt.carestream.com www.zeiss.com/metrology www.creaform3d.com/ndt www.gradientlens.com www.scopes.com/v5_videoscope www.mchidascope.com www.olympus-ims.com www.proceq-usa.com www.scienscope.com www.spectroline.com www.sunteccorp.com www.tedndt.com www.tuvris.com www.varian.com/sip www.verimation.com www.yxlon.com

This index is provided as a reader service. The publisher assumes no liability for errors or omissions. 40 NDT ● FEBRUARY 2012

NDT SPECIAL SECTION

www.ndtmag.com

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.

OMNISCAN MX2 Be truly in touch with phased array t
#SJHIU
MBSHF
TJ[F
TDSFFO t
'BTU
JOUVJUJWF
UPVDI
TDSFFO
JOUFSGBDF t
'VMM
TDSFFO
NPEF EPOCH 1000i t
"EWBODFE
8FME
0WFSMBZ
Flaw Detector t
)JHIDBQBDJUZ
EBUB
TUPSBHF Now with Encoded C-scan t
'BTU
mMF
USBOTGFS and Weld Overlay t
%FTJHOFE
GPS
*1 Visit www.olympus-ims.com
t
JOGP!PMZNQVT/%5DPN

Y.Multiplex Truly all-purpose

Q Highly dynamic radioscopy (HDR) and CT in one universal X-ray inspection system Q Automatic defect recognition (ADR) Q Programmable inspection workflow for CT and radioscopy Q Depiction of CT tomograms directly in the system software YXLON A division of Comet Technologies USA Akron 3400 Gilchrist Road Akron, OH 44260-1221, USA T: +1 330 798 4800 www.yxlon.com

Technology with Passion

February 2012

A Special Section to Quality Magazine

www.qualitymag.com

IMPROVING YOUR MANUFAC TUR ING PROC ES S

March 14-15, 2012 Fort Worth Convention Center Fort Worth, Texas

SHOW GUIDE

W E N Mahr Federal Hand Tools

The New REFERENCE for Digital Calipers

New REFERENCE system means the zero position needs to be set only once High degree of protection against shop dust and coolants - IP67 Easy data transfer with MarConnect MarConnect

IP67

USB

RS232C

Available for fast delivery

Digimatic

-

+ MICROMETERS

SNAP GAGES

AIR GAGING

INDICATORS

CALIPERS

ID/OD GAGES

Mahr Federal - The Application Specialist Contact: Mahr Federal Inc., Providence, RI, Phone 800-343-2050, Fax 401-784-3246, E-mail: [email protected], Internet: www.mahr.com

WELCOME TO QUALITY EXPO TEXAS 6

CONFERENCE AGENDA

12

FLOOR PLAN

14

EXHIBITOR INDEX

16

COMPANY DIRECTORY

20

AD INDEX

EXPO HOURS: MARCH 14, 2012 8:00 A.M. - 5:00 P.M. EXPO HOURS: MARCH 15, 2012 8:00 A.M. - 5:00 P.M.

A

BURST of Automation!

PRODUCTION GAGING SOLUTIONS Custom Medical Taper Gages Micro II Two Channel, Three Display air gage readout for fast and reliable inspection of internal and external taper in products such as

tapers. Jet Engine Turbine Blades Nickel Cast Alloy at 100x

EcoMet-AutoMet Pro with the NEW, fully automated BURST Dispensing System

Western Gage Corporation

®

Solutions for Materials Preparation, Testing and Analysis

Excellent Results. Easily Repeatable.™

www.buehler.com

2

Camarillo, CA Ph 805 4451410 FAX 805 4457530 Email: [email protected] Web Site: westerngage.com Supplying dimensional air gages to assure the quality of precision parts since 1968.

YOUR

ADVANTAGE

IS

S TA RRETT

I NNO VATI O N

THE NEXT BIG

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.

To learn more, call 978-248-3551 or scan.

CONFERENCE INTRO OPTIMIZING QUALITY MANAGEMENT CONFERENCE

Fundamental training and best practice tools to help you ensure quality, reduce costs, streamline processes, and deliver the value that customers expect. Whether you are looking to refresh your knowledge, gain new ideas, or develop your skills-set, this two-day conference will provide you with essential in-depth analysis and expert advice on the following key topics:

Save Time. Save Money. with automated gage systems from D90 Wheel Balancing

CONTROL GAGING ZRUOGFODVVLQSURFHVVFRQWUROIRURYHU