Quality July 2011

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JULY 2011, VOLUME 50/NUMBER 7 WWW.QUALITYMAG.COM

TABLE OF

CONTENTS QUALITY MAGAZINE

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JULY 2011

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VOLUME 50

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NUMBER 7

DEPARTMENTS 6

FROM THE EDITOR

Comparing Salaries 8

INDUSTRY NEWS

Positive Global Outlook for Industrial Manufacturing M&A Relationships Improve Among Automakers, Suppliers GE Opens Sustainable Source: Creaform

Manufacturing Center 18 FACE OF QUALITY

Enhance Your Quality Culture

20 FEATURES

19 OTHER DIMENSIONS

Training?

50 YEARS OF QUALITY

22 HANDHELD GAGES: THE INDUSTRY’S WORKHORSE Every shop has a variety of handheld gages hanging around. You may use them every day and not even give them a second thought. This month Quality takes a look back at the industry’s workhorse.

28 CERTIFICATION/REGISTRATION GUIDE Companies provide information on the standards in which they specialize.

30 SERVICES GUIDE Companies provide information on the specific calibration, management and measurement/test/inspection and services they offer.

42 SOFTWARE SELECTION GUIDE The Software Selection Guide highlights products from various companies that distribute to test, inspection and measurement markets. Products ranging from CMM programming and simulation to ISO software are highlighted.

20 QUALITY 101

Back to Basics with 3-D Optical Measurement 62 CASE STUDIES

Quality Measurement for the Automotive Market Scanning to Fit 66 QUALITY PRODUCTS 70 CLASSIFIEDS 72 ADVERTISING INDEX

NEXT MONTH

QUALITY MANAGEMENT

52 MONEY MAKES A COMEBACK Quality professionals are seeing more money line their pockets.

Inline Gaging Surface Measurement Document Control Supply Chain Quality

JULY 2011, VOLUME 50/NUMBER 7 WWW.QUALITYMAG.COM

ABOUT THE COVER

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It’s been a bumpy road the past few years, but now that the economy has leveled out somewhat, the quality professional is receiving his proverbial piece of the pie. Source: Zygo Corp.

QUALITY | July 2011

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QUALITYMAG.COM

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

Available On-Demand CAM Analytics Manufacturing Processes Quality In the case of parts produced on well-maintained CNC equipment, nearly all problems that result in deviation from specification can be eliminated at the front end of the manufacturing process using powerful analytical tools available in the CAM software. This is essential in many industries where short runs mean that a single defective part could prevent a project from being profitable. Quality Software & Analysis: Is Your Process Performing? One of the real treats of working in a statistical process control (SPC) software company is the exposure to a wide range of SPC applications. The use of process performance and capability indices is a consistently top-ranking concern for our client-base, which extends globally across tens of thousands of clients in all types of industries. Readers Respond: Is Quality Defined in Terms of the Customer? In the first of Qualitymag.com’s Reader’s Respond series, quality professionals tackle the debate about who really dictates quality. Visit www.qualitymag.com to weigh in with your opinions today.

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

Eddy Current Testing: Its Many Benefits and Applications Measurement 101: Essential Knowledge August 9, 2:00 p.m. ET CAD-Based Inspection Using Contact Measurement

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

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

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

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

NOW PLAYING ON Q-CAST

NOW PLAYING ON Q-TUBE

Three-Part Interview with Quality Professional of the Year

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

Quality Leadership 100 Companies Laser Radar Slashes Inspection Time Remote Visual Inspection Equipment

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QUALITY | July 2011

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

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FROM THE EDITOR

COMPARING SALARIES A FAIR DAY’S WORK FOR A FAIR DAY’S PAY.

A GILLIAN CAMPBELL

nnual salaries for quality professionals are on the rise…finally. In Quality’s 11th Annual State of the Profession Study, respondents indicated that salaries average $78,505 this year, a 6% increase from last year’s average annual salary of $74,028. Still, that $78,505 isn’t quite enough to cover the $110,000 that Dallas Mavericks’ owner Mark Cuban reportedly paid during his team’s post-finals celebration—$90,000 for a bottle of Ace of Spades champagne, plus a $20,000 tip. Nor is the average quality professionals’ salary anywhere near that of NBA finals MVP Dirk Nowitzki’s $17.3 million, 2011 NBA MVP Derrick Rose’s $5.5 million or Stanley Cup Finals MVP Tim Thomas’ $6 million. And these figures don’t even take into account the millions they make every year from endorsements. As the NFL lockout drags on, Commissioner Roger Goodell and Jeff Pash, the NFL’s lead labor negotiator, have had their salaries reduced to $1 each while the league’s labor impasse is unresolved. Even with their $1 salaries, I doubt they’re having a hard time making ends meet. Dream as we might, most of us will never take home anywhere near an athlete’s salary. According to the Bureau of Labor Statistics, the average annual salary in the United States is $44,410, so while quality professionals take home much less than professional athletes, they still take home 43.4% more than the average worker. Let’s take a look at the annual salaries from a variety of other industries, as reported by the Bureau of Labor Statistics Web site: • Dentists, $158,770 • Lawyers $129,440 • Air traffic controllers, $110,280

• Nuclear engineers, $101,500 • Police officers, $55,620 • Elementary school teachers (excluding special education), $54,330 • Firefighters, $47,730 • Painters, $26,680 • Childcare workers, $21,110 • Fast food cooks, $18,540 Of course, many people don’t go into a particular career because of the money. They do it because they enjoy the work, want to make a difference in their own way, or they simply have to pay the rent or mortgage. When I visited the Daimler Trucks North America Cleveland Truck Manufacturing Plant in Cleveland, NC, earlier this year, I spoke with UAW representative Chris Smith. He mentioned that, in part, their contract labor agreement is about doing a fair day’s work for a fair day’s pay. When it comes right down to it, isn’t that all we really want—to be paid fairly for the work we undertake each and every day? Do you feel you are fairly compensated for the work that you do? Share your thoughts with me at [email protected], or with other members of the Quality community at the Quality Magazine LinkedIn Group page, the Quality Facebook page and on Twitter at http://twitter.com/QualityMagazine.

Gillian Campbell, Editor [email protected]

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

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Darryl Seland, Editor in Chief [email protected]

Christopher Sheehy, Audience Development Audience Development Manager

Gillian Campbell, Editor [email protected]

Katie Jabour, Audience Development Multimedia Specialist

Genevieve Diesing, eMedia Editor [email protected]

Catherine M. Ronan, Audience Development Corporate Audience Audit Manager

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

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QUALITY | July 2011

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CORPORATE DIRECTORS Publishing: Timothy A. Fausch Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Conferences & Events: Emily Patten Clear Seas Research: Beth A. Surowiec

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COMING EVENTS SEPTEMBER 13-15 MATERIALS TESTING 2011 Telford, United Kingdom British Institute of Non-Destructive Testing www.materialstesting.org 20-22 QUALITY EXPO, Chicago, UBM Canon, (310) 445-4200 www.canontradeshows.com/expo/qexpo11

BUSINESS NEWS | COMING EVENTS | PEOPLE NEWS | MERGERS

OCTOBER

POSITIVE OUTLOOK FOR GLOBAL INDUSTRIAL MANUFACTURING M&A

5-6 2011 NORTHEAST SHINGO PRIZE CONFERENCE, Springfield, MA, The Greater Boston Manufacturing Partnership (617) 287-7630, www.neshingoprize.org 16-20 MATERIALS SCIENCE & TECHNOLOGY 2011 Columbus, OH, ACerS, (614) 794-5894 www.matscitech.org 24-28 ASNT FALL CONFERENCE AND QUALITY TESTING SHOW, Palm Springs, CA The American Society for Nondestructive Testing, (800) 222-2768 www.asnt.org/events/calevents/ calevents.htm

PEOPLE NEWS Lecky Integration (Little Falls, NY), a technical consultant company that partners with government agencies, system integrators, OEMs, Fortune 500 companies and entrepreneurial start-ups, has doubled in size since the start of the new year. Recent hires include: • JOSH JOHNSON, a graduate of William and Mary with a degree in computer science and a graduate of Full Sail University, who also holds a bachelor’s degree in Game Development. • DUSTIN HOLTZ, a graduate of Full Sail University, with a bachelor’s degree in Game Development. DON MANFREDI has joined Coherix (Ann Arbor, MI) as vice president of the firm’s automotive operations in the Americas. Coherix is a pioneer in the development of 3-D machinevision technology to detect manufacturing defects in powertrain and other precision automotive components. Renishaw plc’s (Gloucestershire, UK) Chairman and Chief Executive SIR DAVID MCMURTRY has been elected as a fellow of the Royal Society, the United Kingdom’s national academy of science. McMurtry will join a fellowship of the most eminent scientists, engineers and technologists from the United Kingdom and the Commonwealth, all of whom are elected for life through a rigorous peer review process on the basis of excellence in science.

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QUALITY | July 2011

NEW YORK, NY—A significant increase in merger and acquisition (M&A) volume and value in the first quarter of 2011 signals a positive outlook for global industrial manufacturing deal activity, according to Assembling Value, a quarterly analysis of M&A activity in the global industrial manufacturing industry by PwC US. While smaller deals and deals with undisclosed values remained the drivers of activity, the number of mega, large and middle market deals in the first quarter of 2011 are on track to exceed 2010 levels, according to PwC. In the first quarter of 2011, there were 36 deals worth more than $50 million amounting to $16.6 billion, compared to 14 deals totaling $2.3 billion in the first quarter of 2010, an increase of 157% in volume and 622% in value. According to PwC, a recovery of mega deal activity in the first quarter of 2011 also helped contribute to the rise in average deal value to $500 million from $200 million in the first quarter of 2010. There were four transactions with value of at least $1 billion in the first quarter of 2011, which represented approximately 67% of total deal value, or $11.2 billion, compared with no mega deals in the first quarter of last year and 10 in all of 2010. “Increasing confidence in the continuing global economic recovery combined with stronger balance sheets, improved financial markets and greater credit availability should create favorable conditions for deals and further stimulate industrial manufacturing M&A activity in the coming months,” says Barry Misthal, U.S. industrial manufacturing leader for PwC. “We expect to see ongoing global infrastructure

spending and an increase in mega deal activity if the global economy continues to recover, capital becomes more accessible and emerging and developing markets experience significant growth.” Consistent with levels set in recent quarters, strategic investors led first quarter deal activity with 72% of deal volume for transactions worth more than $50 million, while financial investors contributed approximately 28%. According to PwC, financial investors have become increasingly active in mega deals—contributing half of first quarter 2011 mega deal activity with $6.3 billion—signaling their strong comeback to the M&A scene. Non-U.S. affiliated deals continued to dominate M&A activity as companies looked to gain a presence in emerging and developing markets with higher growth potential. During the first quarter of 2011, deals excluding U.S. targets and/or buyers represented 69% of deal value with 24 deals worth more than $50 million, amounting to $11.5 billion. The majority of deals in the first quarter of 2011 came from the U.K. and Eurozone, and Asia and Oceania regions. Thirty-nine percent of targets and 28% of acquirers were in the UK and Eurozone region while 36% of both targets and acquirers were in Asia and Oceania. “Due to a more favorable regulatory environment and advanced capital markets, U.K. and Eurozone targets are likely to be a major catalyst of deal activity, while the Asia and Oceania region also continues to be attractive for its high economic growth and lower production costs,” adds Misthal. “After a strong increase in 2010, North America has significantly decreased its contribution to deal volume, partly because of slower economic recovery and less attractive market conditions.”

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

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Globalization has become a major driver for cross-border M&A activity due to increased deregulation, privatization and corporate restructuring, according to PwC. In the first quarter of 2011, cross-border deals represented 50% of total deals valued at more than $50 million with 18 transactions, driven by companies seeking to gain market share in new, more attractive markets. “As the global economy continues to recover, we expect that companies will seek to gain competitive advantage by broadening their international presence and may engage in cross-border transactions to follow customers or gain new ones,” continues Misthal. “With M&A activity increasing across the globe, executives are facing talent management challenges, including organizational design, integration planning and the cultural blend between acquirer and target. Companies should consider having a disciplined approach to employee integration, which will help them achieve desired synergies, build momentum and instill confidence among stakeholders.” The industrial machinery category realized the largest increase in deal volume and represented the primary driver of activity during the first quarter of 2011, accounting for 56% of total deals worth more than $50 million, including two of the four mega deals in the first quarter. The two remaining mega deals of the first quarter of 2011 came from the electronic and electrical equipment sectors. Rubber and plastic products also increased in volume, accounting for 19% of deal activity, compared to 14% of deals in all of 2010. For a copy of Assembling Value, PwC’s quarterly analysis of M&A activity in the global industrial manufacturing sector, visit www.pwc.com/us/ industrialproducts.

WORKING RELATIONS IMPROVING AMONG DOMESTIC AUTOMAKERS AND SUPPLIERS DETROIT—According to the 11th annual study of working relations between the six North American automakers and their suppliers, the U.S. Big Three automakers: Ford, Chrysler and General Motors—continue to show steady improvement, and the Big Three Japanese automakers: Honda, Toyota and Nissan—continue to slip.

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NEWS ASSOCIATION NEWS

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Twenty-nine engineers and scientists from industry and academia now have the prestigious SAE INTERNATIONAL (SAE, Warrendale, PA) status of SAE Fellow. SAE Fellowship status is the highest grade of membership bestowed by SAE International. It recognizes outstanding engineering and scientific accomplishments by an individual that have resulted in meaningful advances in automotive, aerospace and commercial-vehicle technology. The program, established in 1975, recognizes an average of 20 worldwide recipients for this honor each year. The 2011 recipients, listed in alphabetical order, include: • Dr. Ewa A. Bardasz, technical fellow, Lubrizol Corp. • Dr. Bryan L. Dodson, executive engineer, Continuous Improvement/ Six Sigma, SKF, USA

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• Michael C. Dudzik, vice president, Science & Technology, Washington Operations/Corporate, Lockheed Martin Corp. • Dr. Wayne A. Eckerle, vice president, Research & Technology, Cummins Inc. • Horacio Aragonez Forjaz, executive vice president, Corporate Affairs, Embraer (Empresa Brasileira de Aeronautica S.A.) • Dr. Jaal B. Ghandhi, Grainger professor of Sustainable Engineering, Mechanical Engineering, University of Wisconsin-Madison • Dr. Mircea Gradu, director, Transmission and Driveline Engineering, Head of Virtual Analysis, Chrysler Group LLC • Greg W. Henderson, director, Product Lifecycle Management, retired, Lockheed Martin Aeronautics Co. • Keith Jackson, chief technology officer, Electrical Power and Control Systems, Rolls-Royce PLC • Dr. Linos J. Jacovides, director, retired, Delphi Research Labs Badih A. Jawad, Ph.D., professor and chairman, A. Leon Department of Mechanical Engineering, Lawrence Technological University

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QUALITY | July 2011

• Richard E. Kleine, vice president of Quality and Business Enterprise, Mid Range Engine Business, Cummins Inc., and the 2011 president of SAE International

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NEWS • Dr. Ming-Chia Daniel Lai, professor, Mechanical Engineering, Wayne State University • Patrick Leteinturier, senior principal, Automotive Systems, Infineon Technologies AG • Paul A. Machiele, center director, Assessment and Standards Division, U.S. Environmental Protection Agency (EPA) • Dr. Jeffrey D. Naber, director, Advanced Power Systems Research Center and Associate Professor, Department of Mechanical Engineering-Engineering Mechanics, Michigan Technological University

ASSOCIATION NEWS

• Marc Parent, president and chief executive officer, CAE Inc. • Dr. Charles E. Roberts, Jr., Institute Engineer, Engines, Emissions and Vehicle Research Division, Southwest Research Institute • Gary W. Rogers, PE, president and CEO, FEV Inc. • Dr. Pradeep K. Rohatgi, distinguished professor and director, Composites and Advanced Materials Manufacture Centers and Tribology Laboratories, University of Wisconsin-Milwaukee • Dr. Prakash T. Sathe, senior vice president, Engineering & Business Development, Rapid Global Business Solutions Inc. (RGBSI)

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2011 Training Courses Courses, dates & locations: www.dnvtraining.com or call for a catalog 1-800-486-4524

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QUALITY | July 2011

CONTINUED

The 2011 North American OEM Tier One Supplier Working Relations Study, conducted annually by Planning Perspectives (Birmingham, MI), tracks supplier perceptions of working relations with automaker customers in which OEMs are ranked across the six major purchasing groups broken down into 14 commodity areas. The results of the study are used to calculate the Working Relations Index (WRI) based on 17 working relations variables. This year, 451 suppliers participated, representing 63% of the six automakers’ annual buy. Ford continues to lead the U.S. automakers in having the best relations with its suppliers staying in third place overall, while GM and Chrysler continue to improve. Chrysler, while remaining in last place, has had its second straight year of significant improvement. Among the Japanese automakers, Honda, which was in first place overall for the past two years, has continued to drop and has slipped to second place behind Toyota, which appears to have bottomed out, while Nissan remains stuck in neutral in fourth place. Comparing the six U.S. and Japanese automakers overall, Toyota is in first place, followed by Honda, Ford, Nissan, GM and Chrysler. This year, 540 sales persons from 415 Tier 1 suppliers—representing 1,984 buying situations and 63% of the OEMs’ annual buy—responded to the survey. Demographically, the supplierrespondents represent 37 of the Top 50 North American suppliers, 63 of the Top 100 and 80 of the Top 150 North American suppliers. The study culminates in the Working Relations Index (WRI) which is a quantitative ranking by suppliers of their working relations with each of the six OEMs.

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• Victor E. Saucedo, senior manager (retired), F-117 Program, Lockheed Martin Aeronautics Co.

• Dr. Patrick B. Usoro, technical fellow, Vehicle Development Research Lab, General Motors Research & Development

• Dr. Myoungho Sunwoo, professor, Automotive Engineering, Hanyang University

• Dr. Bryan D. Willson, professor of Mechanical Engineering and director of the Engines & Energy Conversion Laboratory, Colorado State University

• Dr. Galina M. Susova, head, Quality Management System Department, National Institute of the Aviation Technologies • Dr. Tau Tyan, Safety CAE Engineer, Safety Methods Development, Ford Motor Co.

• Dr. Jianwen James Yi, technical leader, Powertrain Research and Advanced Engineering, Ford Motor Co. • Dr. Jianwei Zhang, vice president, China Automotive Technology and Research Center (CATRC)

PRATT & WHITNEY AWARDED $1.13B CONTRACT FOR F135 ENGINE PRODUCTION EAST HARTFORD, CT—The U.S. Department of Defense has awarded Pratt & Whitney a $1.13 billion contract for F135 production engines to power the F-35 Lightning II. Pratt & Whitney and the DoD have reached an agreement on price and terms for the LRIP 4 contract, originally awarded in July 2010, which contains fixed-price and cost-plus incentive fee elements. This low rate initial production (LRIP) contract includes production, spare parts, sustainment and delivery of the fourth lot of F135 engines. Pratt & Whitney is a United Technologies Corp. company. “This contract provides our customer with a 15% savings on the conventional takeoff and landing/ carrier variant, compared to LRIP 3, and demonstrates our commitment toward meeting aggressive cost reduction goals for the F135 engine,” says Bennett Croswell, president of Military Engines, Pratt & Whitney. “It also speaks to the maturity of our engine, which builds on the proven technology of our F119 engine. The F135 engine has powered all 868 F-35 flights, including 100 vertical landings in the short takeoff/vertical-landing (STOVL) configuration.” The fourth lot of F135 engines includes 18 conventional take-off and landing (CTOL) and 19 STOVL engines. Deliveries for this lot are slated to begin in the fourth quarter of 2011. The engines delivered in LRIP 4 will support the U.S. Services, the United Kingdom and the Netherlands. Pratt & Whitney has designed, developed and tested the F135 to deliver the most advanced fifth-generation fighter engine for the United States and its allies around the world.

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BALL GAGE INSTEAD OF A CYLINDRICAL PLUG GAGE. Save time with the self centering spherical surface of the ball gage. When measuring a large number of holes it can be 100 times faster. Put one or two flats on the ball and find any out-of-round holes. Measure how parallel the space is between two surfaces and or the size. You can get into inside diameters or inside spherical surfaces of rod end bearings.

NEWS AMERICAN SOCIETY FOR QUALITY (ASQ, Milwaukee, WI) announced the following slate of officers for the 2012 term, which includes newly created titles as part of ASQ’s governance improvements plan: • Past Chair–E. David Spong, Boeing Co. (retired), Rancho Palos Verdes, CA • Chair–James J. Rooney, ABSG Consulting, Knoxville, TN • Chair-Elect–John Timmerman, Marriott International Inc., Sterling, VA • Treasurer–William B. (Bo) McBee, HewlettPackard Co., Houston, TX; • Newly Elected Board Member–Joanne D. Mayo, Nortel, Cary, NC and • Newly Elected Board Member–Kathleen Goonan, Mongan Institute for Health Policy, Boylston, MA.

GE OPENS SUSTAINABLE MANUFACTURING CENTER IN SAUDI ARABIA DAMMAM, SAUDI ARABIA—GE celebrated the grand opening of the GE Energy Manufacturing Technology Center.

ASSOCIATION NEWS

CONTINUED

The model works to define the responsibility, accountability and authority of the executive director, the president, the chairman, the office of the president, the board and the office of the president structure, job titles and job descriptions. The ASQ membership approved changes to the current body of governance. Effective immediately, the new titles are: • The office of the president becomes the executive council. • The president-elect becomes chair-elect. • The president becomes chair. • When the president fulfills his term, he then becomes past chair. • Executive director becomes chief executive officer.

The 32,000 square-foot center in Dammam, Saudi Arabia, includes a manufacturing facility for high technology equipment for the power, water and oil and gas industries; a service and repair center for advanced

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

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NEWS

BUSINESS NEWS

PRODUCTIVITY QUALITY INC. (Plymouth, MN) and GDO PRECISION TECHNOLOGY (Eygelshoven, Netherlands) have signed an agreement that names PQI as importer and exclusive North American distributor of GDO’s Nuremberg Stent Inspection-7 system. The NSI-7 system is the result of three years of research and development in close collaboration with stent manufacturers. NSF INTERNATIONAL STRATEGIC REGISTRATIONS LTD. (Ann Arbor, MI), a management systems registration company, has acquired accredited registration company AQA INTERNATIONAL LLC (Columbia, SC) and AQA’s current international operations. As a result, NSF-ISR and AQA-certified companies will benefit from a wider global footprint in China, Korea, India, Turkey and Malaysia; a larger North American presence and a broader array of service offerings. LABSPHERE INC. (North Sutton, NH) has been named company of the year by its parent company, UK-based Halma p.l.c. The annual award recognizes the company with the best all-around performance of the 40 Halma group companies worldwide. While one of the criteria is significant growth in sales and profits, the award also takes into account good governance and overall management of engineering and manufacturing. Metrology equipment supplier NANOMETRICS (Milpitas, CA) opened a Singapore advanced metrology center to support its customer base in Asia. The center should give dedicated support throughout Asia for customers requiring advanced modeling of complex structures and recipe development. It also will act as a training center for regional customers and Nanometrics’ branch offices.

turbine equipment; and a training center to empower Saudi college students. As part of the launch, GE announced an additional $150 million investment in the project, bringing the company’s total commitment to $250 million. The end-to-end goal of the center is key. GE can repair advanced technology gas turbine-related parts locally,

DOUGLAS DYNAMICS INC. (Milwaukee, WI), a designer, manufacturer and seller of snow and ice control equipment for light trucks, announced it was recently ranked No. 3 on MILWAUKEE JOURNAL SENTINEL’S Top 100 Workplaces List in the Top Mid-Size Workplace category. This is Douglas’ second consecutive year on the list, an annual ranking of the top 100 workplaces in Southeastern Wisconsin based on input from employees and workplace attributes. In 2010, Douglas Dynamics was ranked No. 7 in the top mid-size workplace category. ACU-GAGE SYSTEMS (Hudson, NH), a manufacturer of one, two-and three-axis noncontact video and laser measuring machines, has been awarded a contract from the U.S. Treasury Department’s Bureau of Engraving and Printing (BEP) for up to nine measuring systems. AcuGage Systems will supply three-axis measuring systems, which will be used to inspect the registration and alignment of all United States’ paper currency. The systems will be installed in Washington, DC, and in Fort Worth, TX. Global metal cutting and composites processing technology company MAG (Erlanger, KY) has acquired FOREST LINÉ INDUSTRIES GROUP (FLI, Paris, France). Forest Liné specializes in manufacturing systems for aerospace applications, dies/molds, large parts, titanium and composites processing. The company is a technology leader in composite wing and wing box applications, and operates sites in France, Germany, China and Canada, employing about 300. Jean Bertrand Prot will continue as president and CEO of FLI and join the MAG Executive board.

for instance, rather than send them out of the country, to save time and cost. The facility will create 2,000 new jobs, supporting goals outlined in Saudi Vision 2020, the Kingdom’s plan for economic development over the next decade. “As Saudi Arabia forges ahead with its ambitious development plans,” GE vice chairman John

Krenicki said at the opening, “the center underscores GE’s commitment to be closer to our customers who trust us to deliver the latest technologies and services across the energy landscape.” GE currently supports roughly half of the Kingdom’s electricity with more than 500 turbines installed throughout Saudi Arabia.

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NEWS VISTEON RECIEVES 2011 TOYOTA GLOBAL TECHNOLOGY AND DEVELOPMENT AWARD YOKOHAMA, JAPAN—Visteon Corp. received the Technology and Development Award from Toyota at its recent 2011 Suppliers Convention in Nagoya, Japan. The award recognizes noisereduction technology as applied to a low-cost fuel pump controller (FPC). Co-developed with Toyota, the technology is considered a breakthrough in the global automobile industry and is currently patent pending. The Technology & Development Award recognizes suppliers who have greatly contributed to boosting the product appeal of Toyota vehicles by developing world-leading new technologies and products. After strict evaluation, the prestigious award is presented to a select number of suppliers every year. “We are extremely pleased to be recognized by Toyota as a top innovator and technology leader,” says Donald J. Stebbins, Visteon chairman, CEO and president. “We continue to focus on partnering with our customers to create exceptional value.” FPC is an electronic module that controls the speed of the fuel pump according to the driving situation, to ultimately improve the fuel efficiency of the vehicle. By utilizing a proprietary printed wire board topology with a high-frequency direct current—direct current converter circuit, Visteon is able to significantly reduce the radiated electromagnetic noise of the FPC. This innovation also results in reduced weight, size and design complexity, and contributes to fuel economy through cost-effective application of the FPC for improved efficiency of the fuel pump system. The core technology can be applied to virtually all types of motor control systems, including those in electric/ hybrid vehicles. The high-quality FPC using this innovative noise reduction technology has been launched on Toyota’s multiple vehicle models in the Japan and U.S. markets.

regarding the U.S. economy, according to Grant Thornton LLP’s most recent Business Optimism Index, a quarterly survey of U.S. manufacturing business leaders. Only 40% believe the U.S. economy will improve in the next six months, down from 60% three months earlier. At the same time, 26% believe the U.S. economy will get worse, up from 3%.

“There are many factors causing concern amongst U.S. manufacturing leaders,” says Wally Gruenes, manufacturing practice leader at Grant Thornton LLP. “Soaring energy and raw material costs and Japanese manufacturing supply chain disruptions are weighing heavily, as are unresolved U.S. debt reduction issues and a corporate tax rate that still puts the U.S. at a global competitive disadvantage.”

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MANUFACTURING CONFIDENCE IN U.S. ECONOMY DROPS CHICAGO–U.S. manufacturing leaders have turned pessimistic

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July 2011 | QUALITY

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FACE OF QUALITY

ENHANCE YOUR

QUALITY CULTURE WE NEED TO CHANGE THE WAY WE THINK ABOUT QUALITY. Editor’s note: This is part one of a two-part series on enhancing quality culture.

A

JIM

sked to give a short talk to a management class at a local university, I focused on a conversation that I had with Dr. A.V. Feigenbaum at the 2010 ASQ World Conference. We were engaged in a discusL. SMITH sion concerning the growth of quality and the major developments that were being influenced by the global economy. The following is a portion of that discussion and talk with the management class. Organizations and their leadership teams must embrace a different way of leveraging quality and think beyond terms of just preventing defects from getting into the hands of their customers. During the past few years, the environment is such that society demands that businesses deliver highquality value. Leveraging quality will feed all three consumers of an organization’s product—stockholders, employees and customers. Stockholders will be pleased Quality initiatives can no because margins will grow, financial ratios longer be contained to one will be positive and stock process will be department or function. enhanced. Employees will be motivated and engaged because of increased job security and an enhanced financial future. Customers will be happy because they will be getting high cost-price-value because of higher product quality. Quality initiatives can no longer be contained to one department or function. In order to move to the next phase, organizations have to adopt ongoing strategy to embrace quality as the fundamental, day-to-day DNA of its core values. Some of the major challenges influencing organizations include: accelerated changes in product development and manufacturing processes; customer demands for an increasingly higher standard of quality value—not just fewer defects—in the products and services they purchase; state-of-the-art technology in a range of business activities to speed time to market; and global distribution. As a result of these challenges, quality has become a global language for businesses and customers. Fun-

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QUALITY | July 2011

damental to any business’ competitive strength is how effectively it interprets and implements the language of quality, in terms of both technical and quality processes. At the core of this language is the realization that quality is what the customer, not the organization, says it is. This may seem fundamental because quality organizations have been saying this for some time; however, many organizational leaders don’t practice this concept in the board rooms or on the factory floor. Organizations must align all aspects of its operations— including marketing, design, manufacture, distribution and service—in very specific customer value terms. Processes must be focused, established, led and maintained to achieve customer value-based success. Many products, from cars to computers to cell phones, with low levels of defects or complaints in the traditional quality control sense, have experienced disappointing sales results. The reason for the disappointment is that the products do not provide the quality value customers are looking for in today’s markets. Quality needs to become a basis for guiding, empowering and supporting the constant pursuit of excellence by everyone in the organization. Most importantly, leadership has to recognize the basic principle that what makes quality better in one part of an organization, can make quality better in other parts of the organization. Quality has to become a cornerstone for constant management innovation and leadership, which is imperative for survival and growth. To meet the demands of the competitive environment and maintain their quality competitiveness, it is Feigenbaum’s belief that organizations must use their strength and leadership in order to remain economically healthy and f lourish in the future. To do so, organizations should focus on some key quality process areas, which we’ll look at in more detail next month. Coming next month: Five key strategies to enhance your quality culture. Jim L. Smith has more than 45 years of industry experience in operations, engineering, research & development and quality management. You can reach Jim at [email protected].

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OTHER DIMENSIONS

TRAINING?

WHEN IT COMES TO TRAINING, ENSURE STUDENTS UNDERSTAND THE BASICS.

E

very so often I receive a panicked request to provide training in dimensional metrology, or the name of someone who can do it when I’m not available. The urgency of the request is the first clue that someone is in damage control mode. Invariably such requests are the fallout from a quality audit—a finding that has to be fixed in 30 days or HILL COX so, if it can be. Another situation that leads to such requests involves corporate takeovers. A number of processes are applied that include integration, merging and resizing, which usually means expensive, skilled employees are put out to pasture in favor of unskilled, lower-cost newcomers. Panic requests for training usually note that it must be at the customer’s plant and not take more than a half day or so. Basically what is wanted at the end of it all is a warm body that can read an instrument and little Basically what is wanted more. Oh, don’t forat the end of it all is a warm get, each student will require a certificate. body that can read an It’s rather like training instrument and little more. a neurosurgeon in one easy lesson without getting complicated. Technical colleges offer basic training courses, but whether they can meet these requirements is a bit iffy. Still, if you are in such a situation, you should check them out. Discuss your needs with the instructor so everyone is singing from the same sheet music. If you intend to set up your own in-house training program, here are some considerations beyond how to read a micrometer: • Make sure the students can speak the language. By this I mean part feature talk: counterbore, through hole or bore, datums, center-line, blind bore, centerdistance, squareness, chamfer, run-out or TIR, keyway, slot, width, length, diameter, and inch and metric units of measure. • Ensure students understand some metrology basics. Examples would include, compare, accuracy, repeatability, linearity, master, standard(s), zero-setting, offsets, taper, roundness, range, capacity, tolerance, co-efficient of thermal expansion, measuring force, traceability, calibration, surface texture or finish, taper, ovality, parallelism, roundness, lobing, flatness and resolution to name a few.

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• If your company makes, buys or inspects threaded fasteners, elements of screw threads will have to be explained. Examples would include major, minor and pitch diameter, linear pitch, halfangle root, crest, classes of fit, thread wires and threads per inch. • Knowing how the instruments actually work is worthwhile so those using them have some idea where to look when things go off the rails. Simple explanations along with sources of errors when they are used can save a lot of problems in their use and help the instruments gain the respect they are entitled to. That would be my shopping list for folks checking component parts. I couldn’t cover it all in a day and I doubt anyone could absorb most of it, even if I could. Having “trained” your staff as noted above, one thing you’ll have to do is test them to see if they have acquired the skills necessary to take the measurements. The easiest way to do this is to give them items of known dimensions and see how closely their measurements match the known or calibrated values. You may want to use a couple of sample components for this purpose. They don’t have to be correct dimensionally since you are going through a comparative process. Rejected parts can be useful after all. Just keep them labeled so they don’t get mixed up with good parts. Some gages that have been rejected also can be used for such testing, but if they are badly tapered or out of round, you may have to mark the measurement locations so their geometry doesn’t mess things up. In some cases, you may want to use components with geometrical irregularities to see if your students find them. Needless to say, all of these activities should be recorded so an auditor can see that you have actually trained your people and the subjects and skills you taught them. Over the years I have taught classes in metrology and noticed that most people that are given the opportunity to learn more tend to want to do so. This attitude can be quite rewarding for the teacher, particularly when you see the pride when your charges master new skills and understand more about what their job entails. Hill Cox president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

July 2011 | QUALITY

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QUALITY 101 With dynamic referencing, 3-D optical measurement technologies deliver increased accuracy. Source: Creaform

3-D optical measurement solutions sidestep these limitations by enabling automatic positioning and continuous device measurement: the self-positioning concept or dynamic referencing.

BACK TO BASICS WITH

3-D OPTICAL MEASUREMENT

Optical 3-D measuring devices’ shop-floor accuracy, decreased sensitivity to environment and higher measurement pace make them strong contenders to traditional quality control devices. BY DANIEL BROWN

I

t is a known fact: fixed coordinate measuring machines (CMMs) generate high accuracy measurements and can be automated, but they are expensive and offer no portability. In comparison, conventional articulated arms offer increased versatility and portability, but they are highly sensitive to environmental conditions; require a rigid setup; and are ill-adapted for shop-floor conditions. Simply put, the arm solutions eliminated CMM downsides, but also rid CMMs of two of their main advantages: stability of the machine and rigidity of the measurement setup. Optical 3-D measuring devices were developed in recent years mainly to compensate for these flaws, and they are bound to play an increasing role in the world of quality control and metrology. Their increased shop-floor

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QUALITY | July 2011

accuracy, decreased sensitivity to environment and higher measurement pace make them strong contenders to traditional quality control devices. The success of 3-D measurement solutions that combine optics and sensors lies in the fact that they offer the benefit of optics—such as speed, portability, reduced sensitivity to the measurement environment and higher measurement volume—while remaining compatible with known, proven procedures. However, most of these optical measurement solutions still use mechanical technologies that present serious limitations in production environments. They require extreme stability throughout the measurement process, in addition to control templates and heavy bases which are costly, cumbersome and mostly inflexible.

HOW DO 3-D OPTICAL MEASUREMENT DEVICES WORK? The basic principle of this technology is that the optical CMM’s cameras track the position of the part and that of a 3-D scanner or touch probe simultaneously in a locked reference model, which makes measuring possible in all conditions. Factors such as instability in the machine or part setup, vibrations or thermal variations will have absolutely no effect on the output measurement accuracy. The core component of these systems is the dual camera sensor, which continuously measures the position of passive and wireless reflectors located in the measuring volume through optical triangulation. First, the sensor measures the position of targets, which have been previously fixed on a part or on a fixture. This way, the machine reference system is completely locked onto the part, which creates a stable alignment, even if the part, the fixture or the sensor is moved. In the same way, the sensor can measure the position of numerous targets placed on an optical CMM 3-D scanner and accurately locate the latter within the measurement volume. The localization is relative to the part itself, thanks to the targets placed on it. The same dual-camera sensor can be used with an arm-free portable CMM and work to localize the wireless probing apparatus. Therefore, the exact position of the tip sphere’s center also can be processed, and all the functionalities of a manual CMM become available to the operator without the requirement for stability. TECHNOLOGIES BEHIND AN OPTICAL CMM The first step is image processing. The challenge is to detect, with the highest accuracy possible, the 2-D position of each reflector.

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It is not an easy task to accurately localize small dots at a few meters distance to obtain a resolution of a few micrometers. Based on advanced mathematics and physics, highly sophisticated algorithms have been developed to provide 2-D localization of the reflectors with a resolution that can be a thousand times higher than the cameras’ basic resolution. Once all the 2-D coordinates from the images are processed, it is possible to compute the 3-D coordinates of each targets using the basics of photogrammetry. By using the 3-D coordinates of targets placed on the same object, it becomes possible to compute the position of this object, such as the probe, the scanner, a fixture or the part to be measured. 3-D MEASUREMENT FOR EVERYDAY APPLICATIONS Now, we have a 3-D optical CMM— and can proceed to 3-D measurement

Oil & Gas

Optical 3-D measuring devices are bound to play an increasing role in the world of quality control and metrology. Source: Creaform

as with any other type of CMM—but the difference is that we now have a better alternative for micrometerprecision 3-D measurements. With dynamic referencing, 3-D optical measurement technologies deliver increased accuracy, particularly in shop floor conditions. The

Automotive

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Daniel Brown is a product manager at Creaform (Lévis, Quebec). For more information, call (418) 833-4446, e-mail [email protected] or visit www.creaform3d.com.

Machining

Aerospace

‡

Handheld Gages

‡

Calibration Equipment and Services

‡

Linear Measurement

‡Quality

www.gagemaker.com/quality

accuracy of an optical CMM is more than just a specification on a technical sheet. It will remain constant despite the quality of the setup, the environmental conditions or the operator’s level of experience. This technology is highly innovative, but also is based on extensive knowledge and proven technologies. This is a result of more than 20 years of research in image processing and optical triangulation fields and takes advantage of the photogrammetry, which has been commonly used in the aerospace industry for years. For these reasons, 3-D optical measurement technologies are bound to play an increasing role in the world of QC and metrology.

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50 YEARS OF QUALITY

Handheld Gages: The Industry’s Workhorse Every shop has a variety of handheld gages hanging around. You may use them every day and not even give them a second thought. This month Quality takes a look back at the industry’s workhorse. of the tool’s extreme tolerances. Dave DESIRE FOR ACCURACY DRIVES DiBiasio, national sales manager for DIGITAL TOOLS, MARCH 2002 Brown & Sharpe (North Kingstown, Electronic, digital handheld tools RI), says the jump from the analog have been around for more than three micrometer to the digital micrometer decades, but they were somewhat slow was a profound advancement to be accepted. Today, many w QUALITY because of the extremely small suppliers say that digital tool b Desire for Accuracy Drives Digital Tools measurements that the digisales are equal to or greater than m C nondigital tool sales. ttal version can take. “With a “Early on, they were still sstandard micrometer, there is QUALITY somewhat mistrusted by the a main barrel scale that breaks measuring and manufacturing tthe inch down to a 1∕10 inch, world,” says Steve Pike, group aanother scale on the barrel manager, precision measuring tthat breaks it down to thousandths, aand a vernier scale on the bartools, Mitutoyo America Corp. (Aurora, Aurora sandths rel that breaks it down to 10,000ths of IL). “The first ones were just okay. Not an inch,” he says. “Picture trying to use just Mitutoyo’s, but all manufacturers’ this in a standard shop environment, early versions. We struggled with trying which may not be well lit, and tryto make a tough, reliable and depending to look at one scale, then turn the able digital tool with a battery life that micrometer over and look at another was pretty good and a display that was one and go to a third to see which lines readable in low-light conditions,” he are lining up. All to try and determine says. “Now, we have built six or seven that reading. Without skill, there is a generations of digital calipers and it is huge potential for error.” our most popular tool.” The electronic nature of new The digital micrometer took a little micrometers has allowed manufacturlonger to catch on, probably because MEASUREMENT, TEST AND INSPECTION

Handheld measuring tools have withstood the test of time. By Larry Adams Senior Editor

TECH TIPS

䡲 Early manufacturers recognized the need to make it easier for workers to read measuring tools.

䡲 Today’s electronic handheld measuring tools, such as digital calipers and micrometers, offer ease of use, increased accuracy and long life. 䡲 Digital calipers are now appearing on the market that have been rated to protect the tool from an ingress of dust or water jets hitting the tool from any direction.

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QUALITY | July 2011

iceri Smith was a quality-driven man- new employees is quicker. ufacturer. He made wire mesh at his The same can be said of Chris Blanton, plant in Edinburgh, Scotland, and he quality manager for Accurate Bushing Co. wanted to improve quality by providing (Garwood, NJ), who uses handheld digital his workers with a micrometer that they tools. “These tools are used to take dimencould easily read. What he wanted was a sional measurements of high tolerance micrometer on which his workers could aerospace parts, which we fabricate,” he read the numbers and not have to count says. “Our dimensions call for very tight numbers and lines, but there wasn’t such tolerances, ranging up to 0.0001 inch in a micrometer on the market. So he invent- requirements, so digital is the only way to ed one. go. Digital tools, while certainly more Smith designed what is believed to expensive, tend to function better, give be the world’s first more accurate readings “digital” micrometer, and require somewhat and received a patent less training than do sometime between their analog counter1890 and 1893, accordparts. The old analog ing Dr. Victoria Beaustyle does not give us as champ, a Mitutoyoprecise a reading.” funded researcher for A slow start The Hawley Collection, Electronic, digital University of Sheffield handheld tools have (Sheffield, England). been around for more The device, which was than three decades, not electric as today’s but they were somedigital tools are, used a what slow in their mechanical display that showed inch mea- Ciceri Smith developed this “digital” acceptance. Today, many suppliers say surements three ways: caliper in the late 1800s so that his that digital tool sales 10ths, 100ths and employees could more easily and accurately read measurements. The are equal to or greater 1,000ths. It allowed micrometer has a digital display that his workers to quickly shows measurements in 1/10th inch, than nondigital tool sales. and accurately take 1/100th inch, 1/1000th inch. Photo: Copyright of Professor Francis Evans and the “Early on, they were measurements. Hawley Collection, University of Sheffield, still somewhat misCiceri Smith’s desire England, 2000. trusted by the measurto make a micrometer easier for his workers to use may be more ing and manufacturing world,” says Steve than a century old, but today’s quality Pike, group manager, precision measuring experts also have that desire. Experts such tools, Mitutoyo America Corp. (Aurora, as Wilson Silva, quality engineer at the IL). “The first ones were just okay. Not just automotive component manufacturer Mitutoyo’s, but all manufacturers’ early Dana Corp. (Toledo, OH), for instance. versions. We struggled with trying to Silva says that he uses digital tools because make a tough, reliable and dependable he found that the measurements that are digital tool with a battery life that was taken are more accurate and that training pretty good and a display that was read-

QUALITY / March 2002 www.qualitymag.com

ers to go beyond b d even these h miniscule i i l measurements. Today’s digital micrometers can read down to 50 millionths of an inch, DiBiasio says. Digital is not just confined to calipers and micrometers. A slew of handheld measuring tools such as ultrasonic thickness gages, hardness testers, surface analysis tools, height gages, torque wrenches, gap and flush transducers and others have all added electronic capabilities. Ease of use is a big reason; it is much easier to read a number than to count numbers on a vernier scale or lines on the barrel of a micrometer. The growing use of statistical process control (SPC) is another reason. In the past, results would be noted with paper and pencil, a time-consuming process that can lead to transposition errors, papers getting smudged by contaminants and, most importantly, out-of-tolerance conditions that are allowed to continue because some data analysis is not immediately accessible. Digital tools of all stripes usually are available with RS232 serial ports to connect via cable to a personal data assistant, portable data collector, or laptop or PC computer. This eliminates errors by cutting out the paper step, and also makes SPC analysis of measurement data available more quickly, sometimes in real time.

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QUALITY 101: CALIPER BASICS, AUGUST 2007 Calipers are extremely versatile tools for making a wide range of distance measurements, including both outside diameters (OD) and inside diameters (ID). While micrometers are more accurate, they have a limited measurement range, typically several inches. Calipers can span from 2 inches to 4 feet, depending on the length of the scale. External measurements are made by closing the jaws over the piece to be measured, while internal measurements are made by opening up the inside diameter contacts. Depth and other measurements can be made with a depth rod built into the instrument’s beam. There are three basic types of caliper that may be found today in a machinist’s tool chest: • Vernier. The vernier caliper is the original design and still the most rugged. Graduated much like a micrometer, it requires the alignment of an etched scale on the vernier plate with an equally spaced scale running the length of the tool’s

handle. Skillful alignment of the tool and interpretation of the reading is necessary to achieve the measurement tool’s stated accuracy. • Dial. A dial caliper is a secondgeneration caliper. Similar in construction to the vernier caliper, this style replaces the vernier scale with a dial indicator. The indicator is fixed to the moveable jaw and engaged with a toothed rack on the body of the unit. The dial, which is typically balanced, meaning it can move in either plus or minus directions from zero, may be graduated in either inch or metric units. The dial caliper is a dual-purpose tool and can make either direct or comparative measurements. To make a comparison, first measure the reference dimension and set the dial indicator to zero. Then measure the dimension to be compared. The indicator will show how much the compared dimension varies from the original (plus or minus). Another useful feature of the dial caliper are jaws that slide past each

other to allow contact points or depth rod Caliper Basics extensions to fit into narrow openings for small ID measurements. • Digital. In the past 25 years the digital caliper has made its way onto the shop floor. The latest designs provide numerous electronic features that make the device easier to use, yet add little in the way of cost. These include: easy switching between inch and metric units on the readout, tolerance indications, digital output to electronic data collection systems, zero setting anywhere along the caliper’s range and retention of the zero setting even when the caliper is turned off. With no moving parts in the readout, the digital caliper is durable, and newer units are even waterproof. Q UA LITY 1 0 1

3 The latest digital calipers provide numerous electronic features that make the device easier to use, yet add little in the way of cost. Source: Mahr Federal Inc.

The versatility of the caliper, along with its range and ease of use, makes it well suited for a multitude of measuring applications. B Y G E O R G E S C H U E T Z

C

alipers are extremely versatile tools for making a wide range of distance measurements, including both outside diameters (OD) and inside diameters (ID). While micrometers are more accurate, they have a limited measurement range, typically several inches. Calipers can span from 2 inches to 4 feet, depending on the length of the scale. External measurements are made by closing the jaws over the piece to be measured, while internal measurements are made by opening up the inside diameter contacts. Depth and other measurements can be made with a depth rod built into the instrument’s beam. There are three basic types of caliper that may be found today in a machinist’s tool chest:

• Vernier. The vernier caliper is the original design and still the most rugged. Graduated much like a micrometer, it requires the alignment of an etched scale on the vernier plate with an equally spaced scale running the length of the tool’s handle. Skillful alignment of the tool and interpretation of the reading is necessary to achieve the measurement tool’s stated accuracy. • Dial. A dial caliper is a secondgeneration caliper. Similar in construction to the vernier caliper, this style replaces the vernier scale with a dial indicator. The indicator is fi xed to the moveable jaw and engaged with a toothed rack on the body of the unit. The dial, which is typically

balanced, meaning it can move in either plus or minus directions from zero, may be graduated in either inch or metric units. The dial caliper is a dual-purpose tool and can make either direct or comparative measurements. To make a comparison, first measure the reference dimension and set the dial indicator to zero. Then measure the dimension to be compared. The indicator will show how much the compared dimension varies from the original (plus or minus). Another useful feature of the dial caliper are jaws that slide past each other to allow contact points or depth rod extensions to fit into narrow openings for small ID measurements. • Digital. In the past 25 years the digital caliper has made its way onto the shop floor. The latest designs provide numerous electronic features that make the device easier to use, yet add little in the way of cost. These include: easy switching between inch and metric units on the readout, tolerance indications, digital output to electronic data collection systems, zero setting anywhere along the caliper’s range and retention of the zero setting even when the caliper is turned off. With no moving parts in the readout, the digital caliper is durable, and newer units are even waterproof.

MEASUREMENT INFLUENCES

Figures a and b illustrate basic OD and ID measurements. Figures c and d illustrate more complex depth and step measurements. Source: Mahr Federal Inc.

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The biggest problem with calipers is that measurements are subject to variation from one operator to another. Two types of influences contribute to this variation: “feel” or inconsistent gaging force, and subjective, or psychological, factors. Because the caliper is a contact instrument, sufficient torque must

QUALITY | August 2007

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DATA ACQUISITION FOR HANDHELD GAGING, FEBRUARY 2008 When looking for a system to handle data collected by handheld gages, there

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50 YEARS OF QUALITY and trips on the cable, yanking it out of are two choices: wireless and wired. your hands with a lot of force. It could Both systems have their place in induslacerate your hands very easily.” try, and carefully considering the attriAnother problem with butes of each will allow one to cabling is entanglement. “If you make the best decision. c have Paradoxically, one could h five tools in a production make the case that a wireless a and they’re all wired to Data Acquisition area for Handheld Gaging the system’s strength also is its t same multiplexer, they will invariable get tangled,” explains weakness, and that at wired i Wilkinson. “At the end of the system’s strength, too, is its W day, weakness. A wireless system d when they’re all tangled together, someone moves one has no wires—so it has the feat and ture of increased mobility, with gages d they th all come down, which can ruin the tool or injure someone.” that are not tethered to a multiplexer There is the issue of cost. First, while or computer; but this also means that the owner of a wired system has to pay EMI can potentially creep up and ruin for cabling, the owner of a wireless sysor impede an operator’s work. A wired tem has to replace transmitter batteries. system has wires—so it offers an inherSecondly—and more importantly— ent robustness, because EMI cannot are the disparities in initial system cost. compromise an operator’s work; but A wireless system will typically be four cabling also means reduced mobility to five times as expensive as its wired and potential safety issues. counterpart. Wireless systems, then, are As Starrett’s Jeff Wilkinson explains, only advantageous for specific applica“Imagine having a tool with sharp jaws, tions. As Mahr’s George Schuetz points like a slide caliper; now imagine having out, “Wireless transmitters are relatively a tool like that with 20 feet of cabling expensive and are often used in applicarunning from it. You’re holding the tions where cabling is difficult, usually tool delicately and someone walks by |

Q UALITY MEASUREMEN T

|

W

hen looking for a system to handle data collected by handheld gages, there are two choices: wireless and wired. Both systems have their place in industry, and carefully considering the attributes of each will allow one to make the best decision.

WIRELESS SYSTEM COMPONENTS

A standard wireless data acquisition system for handheld gaging usually consists of three things: a transmitter interfaced to the gage, a receiver interfaced to the computer, and software that drives the receiver and collects data from the transmitter, allowing that data to be stored in the computer or transferred to a statistical process control (SPC) program. Both the transmitter and receiver of modern wireless data acquisition systems are often transceivers, meaning that they

Both wireless and wired data acquisition systems for handheld gaging come with distinct advantages. B Y S TE VE W ICHE LE CKI, A S S IS TA N T E D ITO R

send and receive data. Because this functionality allows dialogue between the transmitter and receiver, it provides for the existence of system features that ensure data is received correctly by the computer. Virtually any gage, as long as it is capable of digital output, can be interfaced to a wireless system; the transmitter will connect directly into the gage’s digital output port.

WIRELESS SYSTEMS

Today’s wireless systems can accommodate as many as 120 gages and are capable of transmitting data hundreds of feet under ideal line-of-sight condi-

tions. Furthermore, today’s systems incorporate a robustness and reliability not found in those of the past. This is in part enabled by the common use of transceivers, which helps combat data failure or corruption from electromagnetic interference (EMI) by enabling checks against transmission error. For example, a code can be assigned to a piece of data coming from the transmitter, and if the receiver finds that the code is corrupt, it will ask the transmitter to re-send that data until uncorrupted data is received. The use of transceivers also makes operator feedback possible; when, for example,

TECH TIPS

 Today’s wireless systems can accom-

Wired systems can accommodate

modate as many as 120 gages and are capable of transmitting data hundreds of feet under ideal line-of-sight conditions.

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many gages and data transmission distance is relative to cable length.

When choosing a system, consider

the environment in which the system is to be used as well as what it is to inspect.

QUALITY | February 2008

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where the gage has to be brought to the part—say in a machine—and the cables become a liability to the operator.” A scenario with few gages and easily handled parts, for example, would be better off with a wired system. However, using a large number of gages in a wired system could offset its initial value. “Wireless systems are not inexpensive. But at a certain point, most of the multiplexers used in wired gaging become pretty expensive,” explains Wilkinson. “So once you get more than eight gages, it makes sense to go with wireless. In a large deployment, wireless is cheaper.” While both wireless and wired data acquisition systems for handheld gaging are viable options in industry, the appropriateness of each is application specific. In terms of component versatility, both systems are equal, providing compatibility with virtually any thirdparty software and gage. Therefore, it is the environment in which the system is to be used as well as what it is to inspect that should guide one’s decision-making process.

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QUALITY 101: MEASURE PRECISELY WITH HAND TOOLS, SEPTEMBER 2008 The sense of touch becomes important when using contact measuring tools. A skilled machinist with a highly developed sense of “feel” can readily detect a difference in contact made by changes in a m dimension as small as d Hand Tools 00.00025 inch. While the aacuteness of the sense of touch varies with o iindividuals, it can be developed with practice d aand proper handling of tools. In the human tools h m hand, the sense of touch is prominent in the fingertips. Therefore, a contact measuring tool is correctly balanced in the hand when held lightly and delicately in such a way that uses the fingers to handle or move the tool. If the tool is clumsily or harshly grasped, the sense of touch or “feel” is greatly reduced. Sight and touch are frequently combined by the skilled worker to estimate measurements finer than the graduated QUALITY 1 0 1

 Micrometers combine the double contact of a slide caliper with a precision screw adjustment. Source: The L.S. Starrett Co.

Measure Precisely with

Correct use of hand tools ensures measurement accuracy. BY S C OT T ROBINS ON

D

evelopments in precision measurement have made modern hand tools more accurate and easier to read. Reviewing basic tips on the use of precision instruments can help operators use the tools to their full potential and ultimately save time, reduce errors and increase productivity. Presented here are tips for measuring with three popular hand tools: micrometers, slide calipers and micrometer depth gages.

MICROMETERS

The precision micrometer is the most accurate handheld tool available to skilled operators. Some examples of micrometers include digital, vernier, inside and bench.

Micrometers combine the double contact of a slide caliper with a precision screw adjustment that may be read with great accuracy. To use the instrument, the work piece is placed against the anvil with the left hand while the spindle is turned with the thumb and index finger of the right hand. The measurement should not be forced, as light contact pressure ensures a correct reading.

MEASURING WITH MICROMETERS

Digital micrometers make readings faster and easier for every machinist, regardless of experience. The framemounted counter saves handling time because it can be read without removing fingers from the thimble or the micrometer from the work.

• Keep the work to be measured and the micrometer anvil and spindle faces clean. • For very fine measurements, the micrometer should be set to zero or to a standard by the operator’s “feel,” by the friction thimble or by the ratchet, whichever is being used. • To minimize any frame flexure influence, large micrometers should particularly be set to a standard in the same approximate position, app either vertical or o horizontal, in which they will wil be used. • Avoid rushing measuring work as this may result in inaccurate results. • Do not remove work from a micrometer before taki taking a reading. If a reading cannot be sseen without removing the micrometer, micrometer locking the spindle at the final setting with the lock nut and sliding the micrometer off the work micr piece by the fra frame will be useful. • If a micrometer micromete has been set to a flat standard, operators can get approximately a 0.0001-inch difference when measuring over a round because the same pressure is being applied to a point or line contact.

ADJUSTING A MICROMETER

• Step 1. To eliminate play in the spindle, back off the thimble, insert the spanner wrench into the adjusting nut and tighten just enough to eliminate play. A spanner wrench will likely be furnished with the micrometer at purchase. • Step 2. To adjust zero reading, clean all dirt or grit from measuring faces by gently closing the spindle to the anvil

SIGHT, TOUCH AND ESTIMATION

The sense of touch becomes important when using contact measuring tools. A skilled machinist with a highly developed sense of “feel” can readily detect a difference in contact made by changes in a dimension as small as 0.00025 inch. While the acuteness of the sense of touch varies with individuals, it can be developed with practice and proper handling of tools. In the human hand, the sense of touch is prominent in the fingertips. Therefore, a contact measuring tool is correctly balanced in the hand when held lightly and delicately in such a way that uses

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QUALITY | September 2008

024_QM0908q101.indd 24

the fingers to handle or move the tool. If the tool is clumsily or harshly grasped, the sense of touch or “feel” is greatly reduced. Sight and touch are frequently combined by the skilled worker to estimate measurements finer than the graduated limits of a tool. For example, on the average micrometer graduated to read in thousandths of an inch, the space between the smallest graduations of the thimble is approximately 1⁄16 inch. Variations in size much smaller than a thousandth of an inch can readily be felt and judged by the eye with reasonable accuracy.

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limits of a tool. For example, on the average micrometer graduated to read in thousandths of an inch, the space between the smallest graduations of the thimble is approximately ¹⁄16 inch. Variations in size much smaller than a thousandth of an inch can readily be felt and judged by the eye with reasonable accuracy.

important that the accuracy of handheld measuring tools be maintained, requiring the tools themselves to be cared for properly. There are two main categories of maintenance for hand measuring tools. The first is in response to everyday use and handling. This assumes that the correct tool is selected in the first place, for example, making sure the IP or Ingress QUALITY 101: PROPER CARE OF Protection Rating is suitable. HANDHELD MEASURING TOOLS, The second type of maintenance JANUARY 2010 is specified by formal, periodic and The nature of quality control meadocumented inspection and calibrasurement is continually changing tion routines. Calibration in response to developments t is in coordinate measuring i most commonly performed in-house, but many machines (CMMs) and other f Proper Care quality programs specify technology-laden metrology q additional calibration at instruments. Nevertheless, a accredited labs. These labs the precision and repeatabila provide calibration traceable ity of handheld dimensional p to measuring tools—calipers, t final standards such as NIST (National Institute of micrometers and gages—are N Standards still heavily relied on throughout ut Standard and Technology). Related to calibration is use of gage blocks— most of manufacturing. And as extremely precise artifacts with a care tolerances of manufactured parts regimen all their own. Q become ever tighter, it is even more Q UA LITY 1 0 1

points—thought by some to be ideal for ripping open boxes. This type of misuse can put burrs on the jaws, maybe too small to see, yet capable of throwing jaws out of stated accuracy. Micrometers are commonly misused in operation. Many micrometers include a ratchet-stop feature to assist in making proper workpiece contact by “slipping” to stop closure of the micrometer faces once proper contact is made. Nevertheless, some users vigorously torque the barrel Calipers are prone to misuse; they usually posses ID jaws even after the ratchet starts that come to very sharp points—thought by some to be ideal clicking; this may cause for ripping open boxes. This type of misuse can put burrs on the spindle face to degrade the jaws, maybe too small to see, yet capable of throwing as it is spun or “ground” jaws out of stated accuracy. Source: Mitutoyo America Corp. into the workpiece. As a result, parallelism between spindle and anvil faces may be aversely affected, thus taking the micrometer out of stated accuracy. The most common mishap to affect any precision measuring tool’s integrity is dropping. Any tool dropped to the floor—or shocked against hard machine tool or work As tolerances of manufactured parts become ever tighter, surfaces—should be re-calibrated it is even more important that the accuracy of handheld before it is used again. • Preventive care/storage. Preventive measuring tools be maintained, requiring the tools care begins with an assessment of the themselves to be cared for properly. BY TONY POR TI LLO working environment. If measurement tools are used in a harsh environment, for example, with coolant, The second type of maintenance is he nature of quality control meamist, metal chips and debris, prevenspecified by formal, periodic and docusurement is continually changing tive care can be as simple as wiping in response to developments in coormented inspection and calibration routools clean before storage. dinate measuring machines (CMMs) tines. Calibration is most commonly Wiping down with Kimwipes and other technology-laden metrology performed in-house, but many quality impregnated tissues or with a lintprograms specify additional calibration instruments. Nevertheless, the precifree tissue and denatured alcohol sion and repeatability of handheld at accredited labs. These labs provide will remove whatever material may dimensional measuring tools—calicalibration traceable to fi nal standards be deposited on the tool. This will pers, micrometers and gages—are still such as NIST (National Institute of prevent deposits from solidifying Standards and Technology). Related heavily relied on throughout most of during storage so as to not inhibit to calibration is use of gage blocks— manufacturing. And as tolerances of free movement at next use. manufactured parts become ever tightextremely precise artifacts with a care er, it is even more important that the regimen all their own. Also, calipers and micrometers accuracy of handheld measuring tools should be stored with jaw faces, spinEVERYDAY CARE be maintained, requiring the tools dles and anvils open, gapped slightly themselves to be cared for properly. and not touching. This will prevent • Misuse. The leading cause of damage There are two main categories distortion that can result from the folto hand measuring tools is misuse. of maintenance for hand measurlowing phenomena: Though they may look simple, these ing tools. The first is in response • Any increase in temperature will tools are precision instruments capato everyday use and handling. This cause tools to expand, putting presble of delivering high accuracy: typical assumes that the correct tool is sure on the touching surfaces. dial and digital calipers can measure selected in the first place, for exam• Even with no rise in temperature, to a resolution of 0.0005 inch. Calipers ple, making sure the IP or Ingress the slight pressure of continual conare prone to misuse; they usually posProtection Rating is suitable. tact itself can cause distortion. ses ID jaws that come to very sharp

of Handheld Measuring Tools

T

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QUALITY | January 2010

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Global Registrars Inc. 324 Mineral Ave., P.O. Box 704, Mineral, VA 23117 (540) 894-9570 Fax: (540) 894-9573 [email protected] www.globalregistrars.com ISO 9001: 2008

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Intertek 70 Codman Hill Rd., Boxborough, MA 01719 (800) 810-1195; (978) 929-2100 Fax: (978) 635-8595 [email protected] www.intertek.com/systems-certification ISO 9001: 2008 ISO 13485 ISO 14000 ISO/TS 16949 AS-9100 CE Mark

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IQC LLC P.O. Box 246, Dayton, OH 45401 (937) 223-9000; (937) 673-3732 Fax: (937) 223-9001 ISO 9001: 2008

Notified Body for EU Directives

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Consulting

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Consulting

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Auditing

Alliance International Registrar LLC 47585 Scenic Cir., N., Canton, MI 48188 (734) 667-5399 Fax: (317) 669-2103 [email protected] www.allianceregistrar.com ISO 9001: 2008 ISO 13485 ISO 14000 ISO/TS 16949 ISO 17025 AS-9100 CE Mark ISO 18001:2007 ISO 27001:2005

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Training

Company/Standard Name ABS Quality Evaluations Inc. 16855 Northchase Dr., Houston, TX 77060 (281) 673-2843 Fax: (281) 673-2844 [email protected] www.abs-qe.com ISO 9001: 2008 ISO 13485 ISO 14000 ISO/TS 16949 AS-9100 TL 9000 ISO 28000 ISO 28000; AS 9120; ISO/IEC 27001; ISO/TS 29001; RCMS,; RC 14001; OHSAS 18001; SA 8000, IECQQC 080000; ANSI/ESD S20.20; PED

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TRUaccuracy™ TECHNOLOGY

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Auditing

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Training

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Company 9000 Advisers 290 Edgewater Dr., Middleton, TN 38052 (731) 376-8558 www.9000advisers.com Absolute Clarity & Calibration LLC 109 Main St., Terryville, CT 06786 (860) 583-0502 Fax: (860) 314-1851 Accu-Check Instrument Service Inc. 3160 W. Fair Ave., Lancaster, OH 43130 (740) 654-0500 Fax: (740) 654-3899 Advanced Inspection Services 15150 25th Ave. N., Ste. 200, Plymouth, MN 55447 (763) 473-2258 Fax: (763) 249-8150 [email protected] www.advancedinspect.com OR www.gagesite.com Advanced Measurement Labs Inc. 15840 W. Monte St., Ste. B 109, Sylmar, CA 91342 (818) 833-4444 Fax: (818) 833-7779 [email protected] AIC Quality Services LLC P.O. Box 37361, Houston, TX 77237 (713) 443-4373 American Standards Testing Bureau Inc. P.O. Box 583, New York, NY 10274-0583 (800) 221-5170; (212) 943-3160 Fax: (212) 825-2250 [email protected] www.containertechnologylabs.com AMETEK 8600 Somerset Dr., Largo, FL 33773 (800) 527-9999; (727) 538-6000 Fax: (727) 539-6882 [email protected] www.chatillon.com OR www.lloyd-instruments.com Applied Technical Services Inc. 1049 Triad Ct., Marietta, GA 30062 (770) 423-1400 Fax: (770) 424-6415 Arcadia Aerospace Industries LLC 28000 Airport Rd., A-11, Mooney Ave., Bldg. 110, Punta Gorda, FL 33982 (800) 370-2821 Fax: (941) 205-5701 Automated Precision Inc. 15000 Johns Hopkins Dr., Rockville, MD 20850 (240) 268-0400; (800) 537-2720 Fax: (301) 990-8648 [email protected] www.apisensor.com Automation Innovation Inc. 4604 Eastbrae Ct., Fuquay-Varina, NC 27526 (919) 557-6824 [email protected] OR [email protected] www.auto-in.com OR www.threadinspection.com Bobier Metrology Solutions G4163 Corunna Rd., Flint, MI 48532 (800) 288-2871; (810) 732-4030 Fax: (810) 732-3909 BSI Group America Inc. 12110 Sunset Hills Rd., Ste. 200, Reston, VA 20190 (800) 862-4977; (703) 437-9000 [email protected] www.bsiamerica.com Buehler 41 Waukegan Rd., P.O. Box 1, Lake Bluff, IL 60044 (800) BUE-HLER; (847) 295-6500 Fax: (847) 295-7979 Cal Lab Co. Inc. 17035 Westview Ave., South Holland, IL 60473 (800) 373-1759 Fax: (708) 596-5802

CMM First Article Inspection

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Form/Shape/Surface/Contour

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

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Dead Weight Testers

CMM First Article Inspection

Company Capture 3D Inc. 3505 Cadillac Ave., F1, Costa Mesa, CA 92626 (714) 546-7278; (281) 338-7226 Fax: (248) 426-9001; (860) 940-7234 [email protected] OR [email protected] www.capture3d.com Carl Zeiss Industrial Metrology LLC 6250 Sycamore Ln., N., Maple Grove, MN 55369 (800) 327-9735; (763) 744-2400 Fax: (763) 533-0219 Certified Comparator Products 838 Distribution Dr., Beavercreek, OH 45434 (937) 426-9677 Fax: (937) 426-4816 CGI Inc. 15161 Technology Dr., Eden Prairie, MN 55344 (952) 937-2005; (800) 207-4318 Fax: (952) 937-3018 Cincinnati Precision Instruments 253 Circle Freeway Dr., Cincinnati, OH 45246 (800) 686-3730; (513) 874-2122 Fax: (513) 874-2536 [email protected] www.cpi1stop.com Clark Instrument Inc. 46590 Ryan Ct., Novi, MI 48377 (248) 669-3100 Fax: (248) 669-1199

CNC Machining Centers

CMMs •

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Hardness Testers

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SERVICES GUIDE

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Other

Thread Inspection

Surface Finish Analysis

Spring Testing

Reverse Engineering

Repair Services

Part and Tool Inspection

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Noncontact Inspection

NDT

Metallurgy

Mechanical Testing

Materials Testing

Leak Testing

Laser Inspection

ID/OD Measurement

Gear Inspection

Form and Roundness Testing

First Article Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Dimensional Inspection

CMM Inspection

Capability Studies & Statistical Analysis, PPAP

Capability Studies & Statistical Analysis, Gage R&R

Capability Studies & Statistical Analysis, SPC

Calibration Services

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Six Sigma

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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Vacuum

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Torque

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Pressure/Flow

Optical Equipment

Microscopes

Mass

Magnetic Particle Machines

Load Cells

Levels

Leak Testers

Hard Gage

Hand Gages

Gage Repair

Gage Blocks

Form/Shape/Surface/Contour

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

Dead Weight Testers

CNC Machining Centers

Company Cooper Instruments 400 Belle Air Ln., P.O. Box 3048, Warrenton, VA 20188 (800) 344-3921; (540) 349-4746 Creaform 220 E. Delaware Ave., Newark, DE 19711 (302) 444-6696 Fax: (418) 833-9588 [email protected] www.creaform3d.com C.S.C. Force Measurement Inc. P.O. Box 887,84 Ramah Cir., N., Agawam, MA 01001-0887 (800) 866-3672; (413) 789-3086 Fax: (413) 789-3598 [email protected] www.cscforce.com DataNet Quality Systems 29200 Northwestern Highway, 3rd Floor, Southfield, MI 48034 (248) 357-2200 Fax: (248) 357-4933 [email protected] winspc.com Detroit Testing Machine Co. 46590 Ryan Ct., Novi, MI 48377 (248) 669-3100 Fax: (248) 669-1199 Digital Measurement Metrology 26 Automatic Rd., Unit 4, Brampton, Canada L6S 5N7 (866) 960-9400 www.dmm.ca OR www.calibrationservices.ca Dimensional Measurement Inc. 46989 Liberty Dr., Wixom, MI 48393 (248) 960-8801 [email protected] www.dimensionalmeasure.com DNV Business Assurance 1400 Ravello Dr., Katy, TX 77449 (877) 368-3530; (281) 396-1000 Fax: (281) 396-1903 [email protected] www.dnvcert.com OR www.dnvtraining.com Dorsey Metrology International 53 Oakley St., Poughkeepsie, NY 12601 (845) 454-3111 Fax: (845) 454-3888 www.dorseymetrology.com Dynamic Technology Inc. 3201 W. Royal Ln., Ste. 150, Irving, TX 75063 (214) 723-5600 Eastern Applied Research 6614 Lincoln Ave., Lockport, NY 14094-6109 (716) 201-1115 Fax: (716) 201-1119 EMI Gage 28W144 Industrial Ave., Ste. 100, Lake Barrington, IL 60010 (847) 277-7511 Fax: (847) 277-7911 Engineered Work Systems P.O. Box 82262, Rochester, MI 48308 (248) 652-1741; (248) 895-0725 EtQ Inc. 399 Conkin St., Ste. 208, Farmingdale, NY 11735 (516) 293-0949; (800) 354-4476 Gage Services Inc. 40120 Grand River Ave., Novi, MI 48375 (800) 280-7592; (248) 476-8350 Fax: (248) 476-8535 [email protected] OR [email protected] www.gageservices.com OR www.gageservices.net GHR Associates 103 Kakeout Rd., Butler, NJ 07405 (973) 838-8915 Fax: (973) 838-8915

CMM First Article Inspection

CMMs

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Hardness Testers

CALIBRATION SERVICES

SERVICES GUIDE

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Thread Inspection

Surface Finish Analysis

Spring Testing

Repair Services

Part and Tool Inspection

Noncontact Inspection

NDT

Metallurgy

Materials Testing

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Leak Testing

Laser Inspection

ID/OD Measurement

Gear Inspection

Form and Roundness Testing

First Article Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Dimensional Inspection

CMM Inspection

Capability Studies & Statistical Analysis, PPAP

Capability Studies & Statistical Analysis, Gage R&R

Capability Studies & Statistical Analysis, SPC

Calibration Services

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Six Sigma

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

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Other

Video Equipment

Vacuum

Torque

Tensile Testers

Temperature

Surface Plates

Spring/Compression

Scales/Balances

Pressure/Flow

Optical Equipment

Microscopes

Mass

Magnetic Particle Machines

Load Cells

Levels

Leak Testers

Hard Gage

Hand Gages

Gage Repair

Gage Blocks

Form/Shape/Surface/Contour

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

Dead Weight Testers

CNC Machining Centers

Company Global Certification-USA LLC P.O. Box 1004, Dayton, OH 45401 (937) 673-6077 Fax: (513) 672-0746 Harpco Systems Inc. 29445 Beck Rd., Ste. A205, Wixom, MI 48393-3348 (248) 374-1718 www.harpcosystems.com -Hemco Gage 455 Douglas Ave., Holland, MI 49424 (800) 959-7413; (616) 396-4604 Fax: (616) 396-0413 [email protected] www.hemcogages.com Hexagon Metrology Services Inc. 250 Circuit Dr., North Kingstown, RI 02852 (800) 274-9433; (314) 276-2387 Fax: (314) 878-4895 Hommel-Etamic America 1505 W. Hamlin Rd., Rochester Hills, MI 48309 (248) 853-5888 Fax: (248) 853-1505 [email protected] www.hommel-etamic.com Industrial Imaging Systems LLC 4444 Junipero Serra, Ste. 200, San Jose, CA 95129 (408) 408-4084; (408) 408-4087 Fax: (408) 408-4087; (408) 777-0108 -InfinityQS International Inc. 14900 Conference Center Dr., Chantilly, VA 20151 (800) 772-7978; (703) 961-0200 Fax: (703) 961-1923 [email protected] www.infinityqs.com International Quality Institute N30W5030 Landmark Dr., Cedarburg, WI 53012-2910 (262) 375-8868 IQC LLC P.O. Box 246, Dayton, OH 45401 (937) 223-9000; (937) 673-3732 Fax: (937) 223-9001 IQL Independent Quality Labs Inc. 15 Gray Ln., Ste. #401, Ashaway, RI 02804-1209 (401) 539-8510; (866) 549-2920 Fax: (401) 539-0572 ISOQual International Corp. 24 Mayfair St., Norwood, MA 02062 (781) 762-6664 -Laboratory Testing Inc. 2331 Topaz Dr., Hatfield, PA 19440 (800) 219-9095; (215) 997-9080 Fax: (800) 219-9096; (215) 997-9511 [email protected] www.labtesting.com -Ledford Gage Laboratory Inc. 227 Industrial Dr., P.O. Box 100, Mulvane, KS 67110-0100 (316) 777-9300; (800) 237-GAGE (4243) Fax: (316) 777-2220 [email protected] OR [email protected] www.ledfordgage.com -Mahr Federal Inc. 1144 Eddy St., Providence, RI 02905 (800) 343-2050 Fax: (401) 784-3246 [email protected] www.mahr.com Master Metrology 1041 Cromwell Bridge Rd., Towson, MD 21286 (800) 532-8020 Metrologic Group Services Inc. 28064 Center Oaks Ct., Wixom, MI 48393 (248) 504-6200 Fax: (248) 504-5430 -Meyer Gage Co. Inc. 230 Burnham St., South Windsor, CT 06074 (860) 528-6527; (888) 746-4243 Fax: (860) 528-1428 [email protected] www.meyergage.com

CMM First Article Inspection

CMMs

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Hardness Testers

CALIBRATION SERVICES

SERVICES GUIDE

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Thread Inspection

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Surface Finish Analysis

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Spring Testing

NDT

Metallurgy

Mechanical Testing

Materials Testing

Leak Testing

Gear Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Form and Roundness Testing

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First Article Inspection

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Dimensional Inspection

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CMM Inspection

Capability Studies & Statistical Analysis, PPAP

Capability Studies & Statistical Analysis, Gage R&R

Capability Studies & Statistical Analysis, SPC

Calibration Services

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Six Sigma

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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Vacuum

Torque

Tensile Testers

Temperature

Surface Plates

Spring/Compression

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Scales/Balances

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Pressure/Flow

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Optical Equipment

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Microscopes

Hardness Testers

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Mass

Hard Gage

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Magnetic Particle Machines

Hand Gages

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Load Cells

Gage Repair

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Levels

Gage Blocks

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

Dead Weight Testers

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Form/Shape/Surface/Contour

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CNC Machining Centers

Company Minitab Inc. 1829 Pine Hall Rd.,Quality Plaza, State College, PA 16801-3008 (800) 448-3555; (814) 238-3280 www.minitab.com Mitutoyo America Corp. 965 Corporate Blvd., Aurora, IL 60502 (630) 820-9666; (888) 648-8869 Fax: (630) 978-3501 [email protected] www.mitutoyo.com Nikon Metrology Inc. 12701 Grand River Rd., Brighton, MI 48116 (810) 220-4360 Fax: (810) 220-4300 [email protected] www.nikonmetrology.com Perry Johnson Consulting Inc. 5000 Town Center, Ste. 2002, Southfield, MI 48075 (888) 248-0256; (248) 519-2588 Fax: (248) 247-3366 [email protected] OR [email protected] www.pjcinc.com Pinnacle Partners Inc. 36 Rivers Run Way, Oak Ridge, TN 37830 (865) 482-1362 Fax: (865) 483-7451 [email protected] www.pinnaclepartnersinc.com QC Group Inc., The 5950 Clearwater Dr., Ste. 300, Minnetonka, MN 55343 (952) 895-1150 Fax: (952) 895-1152 Q-PLUS Labs 13765-E Alton Pkwy., Irvine, CA 92618 (949) 380-7758 Fax: (949) 380-7790 [email protected] OR [email protected] www.qpluslabs.com Quad Group Inc. 1815 S. Lewis St., Spokane, WA 99224 (800) 342-2430; (509) 458-4558 Fax: (509) 458-4555 [email protected] www.quadgroupinc.com Quality Vision Services Inc. 1175 North St., Rochester, NY 14621-4942 (866) 815-6618 Fax: (585) 506-4307 R & R Gage 6669-G Peachtree Industrial Blvd., Norcross, GA 30092 (770) 409-9801 R. L. Schmitt Co. Inc. 34506 Glendale, Livonia, MI 48150 (877) 777-9310; (734) 525-9310 Fax: (734) 525-1616 www.rlschmitt.com Renishaw Inc. 5277 Trillium Blvd., Hoffman Estates, IL 60192 (847) 286-9953 Fax: (847) 286-9974 Restor Metrology 921 Venture Ave, Leesburg, FL 34748 (877) 220-5554 Fax: (866) 202-9554 Rotronic Instrument Corp. 135 Engineers Rd., Ste. 150, Hauppauge, NY 11788 (631) 427-3898; (800) 628-7101 Fax: (631) 427-3902

CMM First Article Inspection

CMMs

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Leak Testers

CALIBRATION SERVICES

SERVICES GUIDE

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Other

Thread Inspection

Surface Finish Analysis

Spring Testing

Reverse Engineering

Repair Services

Part and Tool Inspection

Noncontact Inspection

NDT

Metallurgy

Mechanical Testing

Materials Testing

Leak Testing

Laser Inspection

ID/OD Measurement

Gear Inspection

Form and Roundness Testing

First Article Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Dimensional Inspection

CMM Inspection

Capability Studies & Statistical Analysis, PPAP

Capability Studies & Statistical Analysis, SPC

Calibration Services

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Six Sigma

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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SAI Global 2 Summit Park Dr., Ste. 425, Cleveland, OH 44131 (800) 247-0802 (216) 654-0900 [email protected] www.saiglobal.com Scantek Inc. 6430 #C, Dobbin Rd., Columbia , MD 21045 (410) 290-7726; (800) 224-3813 Sciemetric Instruments Inc. 359 Terry Fox Dr., Ste. 100, Ottawa, Canada K2K 2E7 (613) 254-7054 www.sciemetric.com SPC Press/Statistical Process Controls Inc. 5908 Toole Dr., Ste. C, Knoxville, TN 37919 (865) 584-5005; (800) 545-8602 SRI Quality System Registrar 300 Northpointe Cir., Ste. 304, Seven Fields, PA 16046 (724) 934-9000 Fax: (724) 935-6825 [email protected] www.sriregistrar.com Sun-Tec Corp. 46590 Ryan Ct., Novi, MI 48377 (248) 669-3100 Fax: (248) 669-1199 Thread Check Inc. 390 Oser Ave., Hauppauge, NY 11788 (631) 231-1515; (800) 767-7633 Fax: (631) 231-1625; (800) 767-2034 [email protected] www.threadcheck.com Touchstone Measurement Services LLC 2529 Commerce Dr., Ste. F, Kokomo, IN 46902 (765) 454-5888 [email protected] www.touchstone.net Troemner LLC 201 Wolf Dr.,P.O. Box 87, Thorofare, NJ 08086 (800) 352-7705 [email protected] www.troemner.com United Testing Systems Inc. 5171 Exchange Dr., Flint, MI 48507 (800) 578-2800; (810) 732-2800 Fax: (810) 732-2872 -Western Gage Corp. 3316-A Maya Linda, Camarillo, CA 93012-8059 (800) 423-5062 Fax: (805) 445-7530 [email protected] www.westerngage.com Yokogawa Corp. of America 2 Dart Rd., Newnan, GA 30265 (800) 888-6400 Fax: (770) 251-2080 [email protected] www.yokogawa-usa.com OR www.yokogawa.com/us YXLON 3400 Gilchrist Rd., Akron, OH 44260-1221 (330) 798-4800 Fax: (330) 784-9854 www.yxlon.com Zygo Corp. Laurel Brook Rd., Middlefield, CT 06455 (860) 347-8506 Fax: (860) 347-3869 [email protected] www.zygo.com

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Large-Scale Scanning

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X-Ray Fluorescence (XRF)

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Certification/Registration

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Volumetric Error Compensation, Machine Tool Clibration/Repair

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SPC Software

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Coating Thickness Measurement

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Failure Modes and Effects Analysis

QUALITY | July 2011

Other 12

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Video Equipment

Vacuum

Torque

Tensile Testers

Temperature

Surface Plates

Spring/Compression

Scales/Balances

Pressure/Flow

Optical Equipment

Microscopes

Mass

Magnetic Particle Machines

Load Cells

Levels

Leak Testers

Hard Gage

Hand Gages

Gage Repair

Gage Blocks

Form/Shape/Surface/Contour

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

Dead Weight Testers

CNC Machining Centers

Company

CMM First Article Inspection

CMMs

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Hardness Testers

CALIBRATION SERVICES

SERVICES GUIDE

www.qualitymag.com

• Six Sigma

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Implementation, Consulting and Training

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Model Based Inspection

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NVH, Torque, Weld

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Check Fixtures

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Sound and Vibration Instruments and Transducers

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Vision System Inspection

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Other

Thread Inspection

Surface Finish Analysis

Spring Testing

Reverse Engineering

Repair Services

Part and Tool Inspection

Noncontact Inspection

NDT

Metallurgy

Mechanical Testing

Materials Testing

Leak Testing

Laser Inspection

ID/OD Measurement

Gear Inspection

Form and Roundness Testing

First Article Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Dimensional Inspection

CMM Inspection

Calibration Services

•

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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✪ View product spec sheets for these companies at www.qualitymag.com/softwareselector

Company/Software Name Accupoint Software 241 W. Federal St., Youngstown, OH 44503 (800) 563-6250 Fax: (330) 746-6863 InterLink QES Quality, Environmental & Safety Management Software 10.0.0.3 AcquiData Inc. P.O. Box 83,Shared Services Ctr., South Woodstock, CT 06267 (860) 910-4747 Fax: (860) 910-4747 Testream/CS Product Quality Automation System Advanced Systems & Designs Inc. 360 E. Maple Rd., Ste. L, Troy, MI 48083 (248) 370-9919 Fax: (248) 370-9921 SPC1+ Enterprise Altegra 1902 Wright Pl., Ste. 200, Carlsbad, CA 92008 (760) 438-7403 Fax: (760) 438-4013 [email protected] www.altegra.com GageManager - Powerful and Affordable Calibration Scheduling MSA, Gage Inventory Management PlantNet SPC - SPC, Tool Change Scheduling, Downtime Tracking for Machine Shops AQA Co. Inc. P.O. Box 90516, Pasadena, CA 91109 (626) 796-9000 Fax: (818) 790-9015 [email protected] OR [email protected] www.isoxp.com ISOXpress Document Control and Quality Management Software 2011 ASDQMS 360 E. Maple Rd., #L, Troy, MI 48083 (248) 370-9919 Fax: (248) 370-9921 SPC1+ Enterprise AssetSmart 2800 28th St., Ste. 109, Santa Monica, CA 90405 (310) 450-2566 Fax: (310) 450-1311 [email protected] OR [email protected] www.assetsmart.com Asset Management 360 SMART/CMS - Calibration Management System SMART/ENCATS - Enterprise Catalog System AutoData Systems 6111 Blue Circle Dr., Minneapolis, MN 55343 (800) 662-2192; (952) 938-4710 Fax: (952) 938-4693 AutoData ExpertScan with NetE-nable 2.0.15 BellHawk Systems Corp. 2 Jacques Pkwy., Millbury, MA 01527 (508) 865-8070 x301 [email protected] www.bellhawk.com BellHawk Inventory and WIP Tracking and Traceability Blue Mountain Quality Resources Inc. P.O. Box 830, State College, PA 16804-0830 (800) 982-2388 Fax: (814) 234-7077 Blue Mountain Regulatory Asset Manager R3 BSI Group America Inc. 12110 Sunset Hills Rd., Ste. 200, Reston, VA 20190 (888) 429-6178; (703) 437-9000 Fax: (703) 437-9001 www.bsiamerica.com Entropy BuildIT Software & Solutions Ltd. 4999 St. Catherine St., W., Ste. 308, Montreal, Canada H3Z 1T3 (514) 369-4055; (888) 687-2348 Fax: (514) 369-2348 [email protected] www.builditsoftware.com Build!IT

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Media

Application

Computing Platforms

CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Company/Software Name Capture 3D Inc. 3505 Cadillac Ave., F1, Costa Mesa, CA 92626 (714) 546-7278; (281) 338-7226 Fax: (248) 426-9001; (860) 940-7234 Free GOM Inspect GOM Inspect Professional Carl Zeiss Industrial Metrology LLC 6250 Sycamore Ln., N., Maple Grove, MN 55369 (763) 744-2400; (800) 327-9735 Fax: (763) 533-0219 CALYPSO Metrology Software 5.0 -CEBOS 5936 Ford Ct., Ste. 203, Brighton, MI 48116 (810) 534-2222 x4 Fax: (810) 534-0131 [email protected] www.cebos.com CEBOS MQ1 -CyberMetrics Corp. 1523 W. Whispering Wind Dr., Ste. 100, Phoenix, AZ 85085 (800) 777-7020; (480) 922-7300 Fax: (480) 922-7400 [email protected] www.cybermetrics.com Calibration Label Kit CalPro Step-by-step Calibration Procedures CyberSensor Temperature and Humidity Monitor FaciliWorks 8i Hosted Calibration & CMMS/ Enterprise Asset Mgmt. 8.6 FaciliWorks 8i Server Calibration & CMMS/ Enterprise Asset Mgmt. 8.6 FaciliWorks Desktop CMMS/Enterprise Asset Mgmt. 8.1 FaciliWorks PDA Software GAGEtrak Calibration Management Software 6.7 GAGEtrak PDA Software GAGEtrak Portable Calibration Solution GAGEtrak Total Calibration Solution SUPPLIERtrak Supplier Quality Assurance Software 4.6 DataLyzer International Inc. 1857 E. West Maple Rd., Walled Lake, MI 48390 (248) 960-3535; +31-40-2940980 Fax: (248) 960-3539 DataLyzer Spectrum Gage Management DataLyzer Spectrum SPC SPC Quickie SPC Wizard DataNet Quality Systems 29200 Northwestern Highway, 3rd Floor, Southfield, MI 48034 (248) 357-2200 Fax: (248) 357-4933 [email protected] www.winspc.com QualTrend WinSPC Deacom Inc. 950 W. Valley Rd., Ste. 3000, Wayne, PA 19087 (610) 971-2278 Fax: (610) 971-2279 [email protected] www.deacom.net DEACOM Enterprise Resource Planning (ERP) Software Dimensional Metrology Standards Consortium 1228 Enclave Cir., #301, Arlington, TX 76011 (817) 461-1092; (817) 683-6228 Fax: (817) 461-4845 [email protected] OR [email protected] www.dmisstandards.org OR www.dmis.org Dimensional Measuring Interface Standard DMIS 5.2 (ANSI and ISO Standard)

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Company/Software Name Faro Technologies Inc. 125 Technology Pk., Lake Mary, FL 32746 Fax: (407) 333-4181 CAM2 Measure Gagemaker LP P.O. Box 87709, Houston, TX 77287 (713) 472-7360 Fax: (713) 472-7241 [email protected] www.gagemaker.com TDWIN GrayTech Systems Inc. 2950 New Macland Rd., Powder Springs, GA 30127 (770) 499-1510 Fax: (770) 422-8546 RealSPC H & H Servicco Corp. P.O. Box 9340, North St. Paul, MN 55109-0340 (651) 777-0152 [email protected] www.samplingplans.com Acceptance Sampling Plan Designer (TP105/TP414) 3.0 Harold S. Haller & Co. 5 Ashley Ct., Cleveland, OH 44116-2381 (440) 895-0775; (440) 364-6005 HITS (EDO-MCA-MPO-SVA-CCA) Haller Information Technology System Version 3 Harpco Systems Inc. 29445 North Beck Rd., Ste. A205, Wixom, MI 48393 (248) 374-1718 Fax: (248) 374-0022 [email protected] www.harpcosystems.com Quality Plus 4.1 Hertzler Systems Inc. 2312 Eisenhower Dr. N., Goshen, IN 46526 (574) 533-0571 Fax: (574) 533-3885 Gain Seeker Suite Hexagon Metrology Inc. 250 Circuit Dr., N. Kingstown, RI 02852 (800) 274-9433; (401) 886-2000 Fax: (401) 886-2727 PC-DMIS I & R Partners Inc. 1048 Edgewater Cir., Gallatin, TN 37066 (615) 777-9372; (615) 394-3243 Fax: (615) 822-5087 GaugeFlex Data Collection Suite IBS America 24 Hartwell Ave., Lexington, MA 02421 (781) 862-9002 Fax: (781) 862-9003 [email protected] www.ibs-us.com CompliantPro QSYS Professional -InfinityQS International 14900 Conference Center Dr., Chantilly, VA 20151 (800) 772-7978; (703) 961-0200 Fax: (703) 961-1923 [email protected] www.infinityqs.com Data Management System (DMS) Dynamic Scheduler ProFicient 4 InnovMetric Software 2014 Cyrille-Duquet, #310, Quebec City, Canada G1N 4N6 (418) 688-2061 Fax: (418) 688-3001 [email protected] www.innovmetric.com PolyWorks/Inspector PolyWorks/Inspector Probing

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CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Company/Software Name Intelex Technologies 905 King St. W., Ste. 600, Toronto, Canada M6K 3G9 (416) 599-6009 www.intelex.com Intelex Compliance Management Intelex Customer Management Intelex Document Control Intelex Integrated Management System Intelex ISO 9001 Management Intelex Quality Management System Intelex Quality Nonconformances & Product Defect Tracking Intelex Quality Objectives & Targets Intelex Quality Policy Intelex Supplier Corrective Actions Intelex Supplier Nonconformance Intelex Supplier Performance Management System Intelex Training Management Interax Group 66 Richmond St.,P.O. Box 23, Amherstburg, Canada N9V 2Z2 (800) 884-3160 Fax: (866) 778-0006 [email protected] www.interaxgrp.com Paradigm 3 Compliance & Document Control Software James D. Meadows & Assoc. Inc. 170 E. Main, Ste. D-137, Hendersonville, TN 37075 (615) 824-8644 Fax: (615) 824-5262 www.geotolmeadows.com Geometric Dimensioning and Tolerancing (GD&T) per ASME Y14.5M-1994 Launsby Consulting 2830 Bethune Ct., Colorado Springs, CO 80920 (719) 282-1143 Fax: (719) 282-3099 [email protected] www.launsby.com DOE Wisdom 6.4.2 Lennox Hill Ltd. P.O. Box 50490, London, England, U.K. W8 9ES +44 5601 567 990 [email protected] www.lennoxhill.co.uk isoTracker - Document Control isoTracker - Quality Management Software Lighthouse Systems Inc. 6780 Pittsford-Palmyra Rd., Bldg. 3, Fairport, NY 14450 (585) 223-0600 Fax: (585) 223-0620 [email protected] www.lighthousesystems.com Shopfloor-Online 4.9 Lyons Information Systems Inc. 2832 Super Sport Ln., Raleigh, NC 27603 (919) 771-1510; (866) 351-4287 Fax: (919) 341-4304 Lyons Quality Audit Tracking System (LQATS) Manedge Software P.O. Box 29063, Austin, TX 78755 (800) 352-8852; (512) 257-3311 Carmen Documents 5.5 Marposs Corp. 3300 Cross Creek Pkwy., Auburn Hills, MI 48326 (248) 370-0404 Fax: (248) 370-0621 [email protected] www.marposs.com Machine Tool 3D Shape Inspector Software Quick SPC for Windows

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CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Company/Software Name Metrologic Group Services Inc. 28064 Center Oaks Ct., Wixom, MI 48393 (248) 504-6200 Fax: (248) 504-5430 Metrolog XG, SILMA XG, Metrolog V5, SILMA V5 Micro-Vu Corp. 7909 Conde Ln., Windsor, CA 95492 (707) 838-6272 Fax: (707) 838-3985 www.microvu.com InSpec Metrology Software 2.91.0241 MicroRidge Systems Inc. P.O. Box 3249, Sunriver, OR 97707-0249 (541) 593-1656 Fax: (541) 593-5652 [email protected] www.microridge.com WedgeLink Software Keyboard wedge Minitab Inc. 1829 Pine Hall Rd., Quality Plaza, State College, PA 16801 (800) 448-3555; (814) 238-3280 Fax: (814) 238-4383 [email protected] www.minitab.com Minitab Statistical Software 16 Quality Companion by Minitab 3 Quality Trainer by Minitab Mitutoyo America Corp. 965 Corporate Blvd., Aurora, IL 60502 (630) 820-9666; (888) 648-8869 Fax: (630) 820-3418 [email protected] www.measurlink.com MeasurLink Gage Management MeasurLink Gage R&R MeasurLink Process Analyzer MeasurLink Process Manager MeasurLink Real Time MeasurLink Real Time PLUS Optical Gaging Products (OGP) 850 Hudson Ave., Rochester, NY 14621 (585) 544-0400; (800) 647-4243 Fax: (585) 544-8092 SmartProfile Pilgrim Software Inc. 2807 W. Busch Blvd., Tampa, FL 33618 (813) 915-1663 Fax: (813) 915-1948 SmartSolve -PQ Systems 210 B East Spring Valley Rd., Dayton, OH 45458 (800) 777-3020 Fax: (937) 885-2252 [email protected] www.pqsystems.com CHARTrunner 3.6 GAGEpack 9.0 SQCpack 6.5 -Proquis 1015 West Wise Rd., Ste. 200, Schaumburg, IL 60193 (847) 278-3230; (877) 876-3430 Fax: (847) 278-3237 [email protected] www.proquis.com Allclear 2010 Analyzer 8 Allclear 2010 Flowcharter 8 Allclear 2010 Orgcharter 8 Allclear Pro 8 Proquis Enterprise Proquis On Demand Q-PLUS Labs 13765-E Alton Pkwy., Irvine, CA 92618 (949) 380-7758 Fax: (949) 380-7790 [email protected] www.qpluslabs.com 2D Profile Pro 1.8

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CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Company/Software Name QI Macros Lean Six Sigma SPC Software for Excel 2253 S. Oneida St., Ste. 3D, Denver, CO 80224 (888) 468-1537; (303) 756-9144 Fax: (888) 468-1536; (303) 756-3107 [email protected] OR [email protected] www.qimacros.com QI Macros Lean Six Sigma SPC Software for Excel 2011 Quality America Inc. 1984 N. Kolb Rd., Tucson, AZ 85715-4005 (800) 722-6154; (520) 722-6154 Fax: (520) 722-6705 [email protected] www.qualityamerica.com Q-Pulse QMS SPC Explorer Qualtrax Inc. 105 Industrial Dr., Christiansburg, VA 24073 (800) 277-3077 Fax: (540) 382-4701 Qualtrax R&R Fixtures / R&R Sales & Engineering P.O. Box 161, Grand Haven, MI 49417 (616) 847-6045 Fax: (616) 847-6082 FixtureBuilder

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CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Air Gaging Customizable to Meet Your Application Needs • High performance in tough environments • Easy to use submicron inspection of critical diameters and tapers • More air gage display choices • New materials - high chrome alloys improve performance, shorten deliveries • Available for fast delivery

• A fast, accurate, portable gauge for testing aluminum, brass, copper and steel. • Test a variety of shapes, extrusions, tubing and flat stock. • Models available to test thickness up to one inch.

WEBSTER INSTRUMENT, INC. 11856 Mississippi Avenue Los Angeles, California 90025 EST. 1932

www.webstertesters.com

Tel. 800-394-3541 • Fax 310-478-1365 www.qualitymag.com

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

July 2011 | QUALITY

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✪ View product spec sheets for these companies at www.qualitymag.com/softwareselector

Company/Software Name Retriever Technology Ltd. P.O. Box 3, Tenbury Wells, England, U.K. WR15 8YX 441584781444 A2Z MANAGER 1.16 Easy-FMEA 1.08 Sciemetric Instruments Inc. 360 Terry Fox Dr., Ste. 100, Ottawa, Canada K2K 2E7 (866) 900-7054 Fax: (613) 254-5313 QualityWorX 3.11 -SigmaXL Inc. 920 Yonge St., Ste. 803, Toronto, Canada M4W 3C7 (888) 744-6295; (416) 236-5877 Fax: (416) 352-0037 www.sigmaxl.com DiscoverSim Beta SigmaXL 6.11

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QUALITY | July 2011

4/6/11 10:28 AM

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Company/Software Name -StatPoint Technologies Inc. 560 Broadview Ave., Ste. 201, Warrenton, VA 20186 (800) 232-7828 x350; (540) 428-0084 x350 Fax: (540) 428-0089 [email protected] OR [email protected] www.statpoint.com OR www.statgraphics.com STATBEANS Statistical Java Bean Library STATGRAPHICS Centurion XVI.I MultiLingual Edition STATGRAPHICS Centurion XVI.I Professional Edition STATGRAPHICS Online Statgraphics Sigma Express Steudel & Schultz LLC 313 W. Beltline Hwy., Ste. 184, Madison, WI 53713 (866) 271-3121; (608) 271-3121 Fax: (608) 838-8985 AS9100C Employee Pocket Guide & Training Video AS9100C Teledyne DALSA 700 Technology Park Dr., Billerica, MA 01821 (978) 670-2002 Fax: (978) 670-2010 iNspect Sherlock

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Company/Software Name Thread Check Inc. 390 Oser Ave., Hauppauge, NY 11788 (631) 231-1515; (800) 767-7633 Fax: (631) 231-1625; (800) 767-2034 [email protected] OR [email protected] www.threadcheck.com ThreadTech v2.24 for Windows Transformation Software Inc. 375 Michener Rd., Guelph, Canada N1K 1E8 (519) 822-7648 x22 Fax: (519) 822-2633 [email protected] www.transformationsoftware.com PPAP Creator Step Ahead Software Verisurf Software Inc. 1553 Harmony Circle, Anaheim, CA 92807 (714) 970-1683 Fax: (714) 701-0280 [email protected] OR [email protected] www.verisurf.com Verisurf Analysis x5 Verisurf Build x5 Verisurf Measure x5 Verisurf Reverse x5 Verisurf-X Basic x5

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CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Spend less time searching for information

and more time using it

The 2011 QUALITY

SELECTION GUIDES: Software Selector Services Guide Registration/Certification Guide Measurement, Test & Inspection Guide • Search by product category or company name • Downloadable product spec sheets • Alpha company listings • Live web & email links • Product photos

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Company/Software Name Vintara 1714 Franklin St., Ste. 100303, Oakland, CA 94612-3409 (925) 386-0435 Fax: (888) 873-8842 Vintara QMS Waypoint Global 6910 N. Shadeland Ave., Ste. 200, Indianapolis, IN 46220-4274 (317) 624-4037 Fax: (866) 571-5482 [email protected] www.waypointglobal.com Powerway Suite V3.50

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NE CMM First Article Inspection Reverse Engineering DCC Full Automation Capability Contract Inspection & Layout Non-Contact Video Inspection 3D Scanning White Light & Laser Scanning 3D CAD Model Based Inspection On-Site Measurement

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Height Gages Accuracy - Innovation - Value Digimar® 816 CLM • Precise measuring results in your production environment

Q-PLUS Labs

• Simple to use - yet high performance functions • Extremely accurate using double scale system

Multi-Sensor Vision Systems 3D Scanners & Software Portable CMMs CMM’s & Accessories Optical Comparators Optical Video Probes Precision Hand Tools Custom Gages Retrofits

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

July 2011 | QUALITY

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MANAGEMENT

Money Makes a

Comeback Those in research and development earn an average of $87,585, a decrease of 8.5% compared to last year, while those involved in manufacturing management/operations bring home an average of $87,266, a 6.4% increase from last year. In other areas, manufacturing engineers earn an average of $77,379 and those in quality/product assurance/control average $74,894. Quality professionals in the computer and electronic product manufacturing sector bring home the largest paychecks at an average of $87,806. This is followed by the aerospace product/ parts manufacturing sector, which averages $86,599, a 9.5% increase from the previous year. Those in electrical equipment, appliance and component manufacturing average $84,867, and those in medical equipment and supplies manufacturing average $82,717. Last year quality professionals in navigation, measuring, electromedical and control instruments manufacturing took the top spot as the category with the highest paid workers with an average salary of $94,900, but this year salaries fell 18.1% to $77,750.

Quality professionals are seeing more money line their pockets. BY GILLIAN CAMPBELL, EDITOR

I

t’s been a bumpy road the past few years, but now that the economy has leveled out somewhat and manufacturers are starting to see orders come in on a regular basis, the quality professional is receiving his piece of the proverbial pie. Nearly half of the respondents to the 11th Annual Quality State of the Profession Study received a salary increase and are taking home an annual average pay check of $78,504. Compared to last year, an additional 19% of survey respondents are taking home a bit more this year. Building on those numbers, 63% of respondents anticipate a salary increase of their next performance review. THE BOTTOM LINE The average salary for the year’s respondents of $78,504, is a 6% increase from last year’s average annual salary of $74,028. In last

year’s survey, only 29% of respondents received a salary increase, but this year 48% received an increase. Compared to the 20% who received a pay decrease last year, workers this year fared better—only 6% reported a salary decrease, but for those who received a decrease, the average pay cut was 18%. Quality professionals fortunate enough to receive a raise saw an average increase of 5%. For the 46% of respondents whose salaries stayed the same when compared to the previous year, the most often cited reasons were pay freezes, the economic climate and a decrease in sales and/or profits. Not surprisingly, corporate management takes home the largest paycheck with an annual average salary of $109,324, but this is a 5.1% decrease from the previous year’s annual salary of $115,183.

ANNUAL SALARY COMPARED TO LAST YEAR

SALARY INCREASE FROM LAST YEAR

Decrease: 6% 10% or more

11%

Increase: 48% 5% to 9%

19%

4%

12%

3%

36%

1% to 2%

21%

No Change: 46% 0

5

10

15

20

25

30

35

40

45

50

Percent of Respondents

52

QUALITY | July 2011

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MANAGEMENT AVERAGE HOURS WORKED PER WEEK CHANGE IN NUMBER OF HOURS SPENT AT WORK IN PAST YEAR

66 to 70

1%

61 to 65

1%

Remained the Same - 62% 56 to 60

8%

Increased - 33% 51 to 55

14%

46 to 50

28%

41 to 45

35%

36 to 40

Decreased - 5%

11%

35 or less

1% 0

5

10

15

20

25

30

35

40

Percent of Respondents

LENGTH OF CAREER

LENGTH OF EMPLOYMENT AT CURRENT COMPANY

More than 25 years

More than 25 years

13%

21 to 25

21 to 25

7%

16 to 20 11 to 15 6 to 10 3 to 5

8%

0 to 2 Years

15% 15

11%

3 to 5

22%

10

15%

6 to 10

21%

0 to 2 Years

13%

11 to 15

15%

5

20%

16 to 20

8%

0

30%

20

25

30

3% 0

In general, the larger the company an employee works for, the more he can expect to be paid. Those working for companies with 5,000 or more employees average $103,501 annually, a 3.4% increase from last year. Respondents working for smaller companies seem to have been rewarded for sticking it out through the tough times; they received 14.9% increase in salary for an average of $69,576. The region of the country in which quality professionals work also affects their pay. Workers in the Northeast, Midwest and South saw their salaries increase this year. In past years, workers in the West have garnered the largest paychecks, but this year their salaries decreased 5.8% to an average of $78,043. This year workers in the South received a staggering 16.7% pay

54

QUALITY | July 2011

5

10

15

20

25

30

Percent of Respondents

Percent of Respondents

increase to an average of $84,682, while those in the Southeast and Midwest saw more modest salary gains of 6.2% and 5.3%, respectively. As is the case in many fields, quality workers are rewarded for continuing their educations. Workers completing a certificate program brought home, on average, $59,932. Those with a high school diploma brought home an average of $65,586, an 18.5% increase from last year. That is followed by those with an associate degree was worth $69,098; a bachelor’s degree, $80,109; and a master’s degree, $92,084. Quality professionals with a Ph.D. earn an average salary of $140,444, a 34% increase from last year. The lowest salary reported for a quality professional this year of $12,000 was from a male, working at

a company of less than 50 employees. He works in the Midwest as a quality/ product assurance/control specialist in the computer and electronic manufacturing sector, holds a master’s degree and maintains ASQ certification. On the opposite end of the spectrum, the largest salary reported in this year’s survey of $220,000 is from a male who works at a company of more than 5,000, also in the computer and electronic product manufacturing sector. He works in the Northeast in manufacturing management/operations, has a master’s degree and is a Six Sigma champion. The good news is that 63% of respondents expect an increase in their salary at their next performance review. Another 35% expect no changes in salary compensation and only 1% expects a decrease in salary.

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AVERAGE QUALITY PROFESSIONAL AT A GLANCE » Gross Annual Compensation: $78,504

» Average Hours Worked Per Week: 47

» Average Age: 51

» Average Number of Employees Supervised: 11

» Average Years at Current Company: 12

» Primary Job Function: QA/QC (73%)

» Average Length of Career in Years: 20

» Average Company Size: 4,788 employees

When it comes to annual bonuses, again those at larger companies fared better. Almost 63% of quality professionals at companies with more than 5,000 employees took home a bonus to the tune of $8,815 on average. On the other side of the spectrum, only 39% of quality professionals at companies with less than 50 employees took home bonuses that averaged $1,666. The amount of education also affects the size of the bonus. The average bonus for a quality professional with a high school diploma was $1,724, compared to the average $9,400 bonus for a quality professional with a Ph.D. The largest reported bonus of $60,000 is from a respondent who holds a bachelor’s degree. The dollars and cents on the paycheck is only part of the quality professional’s total compensation package. Ninety-five percent of quality workers are offered health insurance, 93% are offered vacation time; 89% are eligible for 401(k), 85% are offered dental insurance; and 79% are offered life insurance. Tuition reimbursement is available for 60%, and on-the-job training is available for 51%.

Last year 17% of companies were not able to meet quality expectations that exceeded in-house capacity. This year

» Highest Level of Education: Bachelor’s Degree (40%) » Job Satisfaction: Moderate

the number has dropped to 8%. The average quality professional wears a variety of hats. As part of their

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July 2011 | QUALITY

55

MANAGEMENT JOB CONCERNS Management Support

41%

Economic Conditions

38%

Job Security

29%

Keeping Current on Technology

23%

Salary

22%

Sufficient Operating Budget

19%

Keeping Current on Regulations

16%

Outsourcing, Privatization

7%

Company Merger or Acquisition

6% 0

10

20

30

40

60

50

Percent of Respondents

PRIMARY JOB FUNCTION Quality/Product Assurance Control

73%

Corporate Management

7%

Manufacturing Engineering

6%

Manufacturing Management/Operations

6%

Research and Development

5%

Other

2% 0

10

20

30

40

60

50

70

80

Percent of Respondents

PRIMARY PRODUCT MANUFACTURED Aerospace Product/Parts Manufacturing

14%

Fabricated Metal Products Manufacturing

13%

Medical Equipment and Supplies Manufacturing

13%

Miscellaneous Manufacturing

12%

Electrical Equipment, Appliance and Component Manufacturing

8%

Plastics and Rubber Products Manufacturing

8%

Motor Vehicle, Body, Trailers, Parts Manufacturing

7%

Primary Metal Manufacturing

7%

Computer and Electronic Product Manufacturing

6%

Machinery Manufacturing

5%

Other Transportation Manufacturing

3%

Navigation, Measuring, Electro Medical and Control Instruments Manufacturing

2%

Furniture and Fixtures Manufacturing

1% 0

2

4

6

8

10

12

Percent of Respondents

56

QUALITY | July 2011

14

16

18

20

quality-related work activities that are part of their primary responsibilities, most respondents (80%) implement solutions to problems; 72% interface with management; 66% deal with customers; 65% document adherence to formal standards such as ISO; 61% deal with suppliers; 57% supervise day-today operations; 52% work on continuing education/training; and 49% are responsible for implementing quality methodologies, such as Six Sigma and lean manufacturing. In 2009, time constraints and budget cutbacks, both at 59%, topped the list of expected job constraints/barriers in the upcoming year. Time constraints continue to be an issue as cited by 65% of respondents. Last year budget cutbacks were cited as a concern by only 44% of those surveyed, and this year the number has dropped even further to 27%. A growing concern among quality professionals over the years has been the lack of management support. This year it is the second most cited barrier (40%) that will impact quality professionals’ jobs. Other barriers mentioned in this year’s survey include dealing with customers, 39%; dealing with suppliers, 36%; skilled labor shortage, 29%; new and existing standards, 26%; integrating in-process measurement, 25%; and making new technology work and information overload, both at 22%. In addition to the barriers and constraints quality professionals deal with on a regular basis, there are a number of issues which they are concerned about. For the past several years economic conditions have kept respondents awake at night, but this year the top concern is management support (41%). While worries about the economy have decreased 12% during the past year, it is still a top concern among 35% of respondents. Closely related, job security is mentioned by 29% of quality professionals as a concern, a 9% drop from last year, and a 15% drop in the past two years. Edging up the list of concerns is the need to keep current on technology, with 23% citing it as a concern, an 8% increase from a year ago. On the positive side, it appears that companies are committing more resources toward improving quality operations during the next three years.

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AGE 60 and Older

JOB SATISFACTION Not Satisfactory: 8%

18%

50 to 59

Moderately Satisfactory: 56%

44%

40 to 49

Highly Satisfactory: 36%

25%

30 to 39

10%

Up to Age 29

3% 0

5

10

15

20

25

30

35

40

45

50

Percent of Respondents

Fifty percent see their companies as willing to commit to more resources, up from 36% two years ago. Only 7% expect their companies to commit fewer resources to quality, down from 19% two years ago. And 43% expect their company to commit the same resources toward improving quality. On par with previous years, when it comes to embracing new quality technology, 35% of companies are willing to be one of the early leaders, while another 35% will wait until others successfully use it. Another 15% are likely to be the last to embrace new quality technology, and another 15% are willing to be on the leading edge. Given the ups and downs of the manufacturing industry the past several years, it is reassuring to know that the number of quality professionals who are highly satisfied in their jobs remained the same this year at 36%. Again this year 56% find their jobs moderately satisfactory, while 8% are not satisfied with their jobs. While working at a larger company may have its advantages such as larger salaries and bonuses, it is interesting to note that companies with more than 5,000 employees also have the largest number of employees who are not satisfied with their jobs (14.5%). TRAINING The majority of companies (79%) offer their employees opportunities for ongoing training throughout the year. For those who took training, quality methodologies such as Six Sigma were the leader with 35% engaging in the type of training. Thirty-two percent of manufacturers took ISO, FDA and other regulatory standards training,

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AVERAGE SALARY BY REGION

Midwest $73,802 Northeast $82,105

West $78,043

South $84,682

WHAT QUALITY-RELATED ACTIVITIES WERE PART OF YOUR PRIMARY RESPONSIBILITIES DURING THE PAST YEAR? (MULTIPLE RESPONSES ALLOWED) Implement solutions to problems

80%

Interfacing with management

72%

Dealing with customers

66%

Document adherence to formal standards (ISO, etc.)

65%

Dealing with suppliers

61%

Supervise day-to-day operations

57%

Continuing education/training

52%

Implementing quality methodologies (Six Sigma, Lean Mfg., etc.)

49%

Increase productivity/utilization

48%

Research new methods and technologies

46%

Evaluate proposals from suppliers

34%

Prepare/review budgets

30%

Transitions to ISO 9000

16% 0

10

20

30

40

50

60

70

80

90

100

July 2011 | QUALITY

57

Percent of Respondents

MANAGEMENT while 32% participated in management training. While training is an important aspect of many jobs and experts stress the importance on on-going training, 21% of respondents did not partake in any training in the past year. For those who participated in training, educational opportunities have taken many forms including: • Self-study, books, 56% • On-the-job training, 49% • Online seminars/Webcasts, 46% • Off-site seminars, 39% • Trade magazines, 37% • Technical training, 34% • Trade shows, 31% • Association training, 30% • On-site seminars, 28% • Courses at local colleges, 21% • Equipment training, 19% When factoring in gender in regards to the type of training respondents

When it comes to the types of skills quality professionals would like to develop in the next year, men are more likely than women to take time management courses, 39.2% vs. 31.9%. Women, on the other hand, would like to develop project management skills (55.1% vs. 45.7%) and problem solving skills (49.3% vs. 43.6%).

have taken in the past 12 months, more men (14.8%) have taken training in equipment operation/repair than women (6.5%). Men also have taken more training in regards to PC software than women, 24.5% vs. 14.5%. On the flip side, half of the women respondents have taken ISO 9000 training compared to 31.4% of men. More women (70.8%) than men (59.9%) have obtained ASQ certification. Look for quality professionals to continue developing their skills in the next 12 months, particularly in the following areas: • Project management, 42% • Problem-solving, 40% • Time management, 33% • Employee supervision, 17% • Teamwork, 15% • Writing reports and proposals, 15% • Finance and accounting, 13% • Public speaking and presentations, 11%

TYPICAL QUALITY PROFESSIONAL Still a male-dominated industry, the number of females in the quality field dipped slightly this year to 14%. The majority of respondents (73%) works in quality/product assurance/ control and has supervisory responsibility. For the 61% who oversee employees, 43% oversee between two to five employees, while another 21% oversee six to 10 employees and 19% oversee 11 to 25 employees. Many (40%) have received a bachelor’s degree

MOST IMPORTANT JOB ATTRIBUTES

GENDER Female: 14%

Feeling of Accomplishment

Male: 86%

46%

Technical Challenge

34%

Good Relationship with Colleagues

33%

Salary

31%

Job Security

27%

Pleasant Work Environment

23%

Chance to be a Team Leader

7% 0

5

10

15

20

25

30

35

40

45

50

Percent of Respondents

HIGHEST LEVEL OF EDUCATION COMPLETED

CERTIFICATION DESIGNATIONS HELD (MULTIPLE RESPONSES ALLOWED)

Ph.D.: 2% ASQ Certification

Master's Degree: 22%

Six Sigma Green Belt

38%

Six Sigma Black Belt

Certificate Program: 10%

28%

Six Sigma Master Black Belt

6%

Six Sigma Champion

6% 0

10

20

30

40

Percent of Respondents

58

High School: 11%

61%

QUALITY | July 2011

50

60

70

Bachelor's Degree: 40%

Associate Degree: 15%

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DO YOU HAVE SUPERVISORY RESPONSIBILITY?

and hold ASQ certification (61%). Eighty-seven percent of quality professionals are 40 or older, with the largest number of respondents (44%) falling in the 50- to 59-year-old category. The average quality professional has been in the industry 20 years and at his current company for 12 years. Thirty percent of respondents have been involved in quality for more than 25 years and of those, 13% of respondents have been at their current company for more than 25 years. Quality professionals are most likely to work in the Midwest (43%) at a company with less than 500 employees (66%). He likely works between 41 to 50 hours per week, which has remained the same for many (62%) during the past year. The typical quality worker is likely part of a team or committee that sets quality goals for: • New processes, 68% • Productivity, 62% • New product development, 54% • New investments, 39% METHODOLOGY A total of 24,775 active, qualified Quality Magazine direct-request subscribers were selected from the domestic (United States only) circulation with e-mail addresses whose job titles included management, manufacturing engineering, manufacturing/operations, quality/product assurance, engineering/technical, and research and development. These subscribers principle product manufactured includes: furniture and fixtures, rubber and miscellaneous plastic products, primary metal industries, fabricated metal products, nonelectronic machinery, electric and electronic equipment, transportation equipment and instruments and related products. A Web-based survey instrument was designed for the study by the Market Research staff of BNP Media. It was sent via e-mail to subscribers between February 7 to February 15, 2011. As an incentive for response, three respondents had a chance to win a $100 American Express gift card. The survey was returned by 627 people for a response rate of 3%. Q

IF YES, HOW MANY PEOPLE DO YOU SUPERVISE?

Yes: 61%

No: 39%

More than 50 people

2%

26 to 50

6%

11 to 25

19%

6 to 10

21%

2 to 5

43%

1 person

8% 0

10 20 30 40 Percent of Respondents

50

OPERATION OF COMPANY (MULTIPLE RESPONSES ALLOWED) Original Equipment Supplier

54%

Components, Parts Manufacturer

45%

Job Shop

21% 0

10

20 30 40 Percent of Respondents

50

60

ANNUAL GROSS COMPENSATION - SALARY ONLY $100,000 or more

20%

$95,000 to $99,999

3%

$90,000 to $94,999

6%

$85,000 to $89,999

7%

$80,000 to $84,999

9%

$75,000 to $79,999

8%

$70,000 to $74,999

9%

$65,000 to $69,999

8%

$60,000 to $64,999

6%

$55,000 to $59,999

4%

$50,000 to $54,999

6%

$45,000 to $49,999

4%

$40,000 to $44,999

4%

$35,000 to $39,999

2%

$30,000 to $34,999

2%

$25,000 to $29,999

1%

Less than $25,000