Quality March 2011

March 2011, Volume 50/Number 3 www.qualitymag.com

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CONTENTS

MARCH 2011 VOLUME 50/NUMBER 3

DEPARTMENTS 6

From the Editor In it Together

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Industry News

Source: R&R Sales and Engineering

SME Selects President, Board of Directors  MEMA Names Industry Champion Award Recipients  Ford to Hire 7,000 Workers

20 Face of Quality

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A Tribute to Dr. Joseph M. Juran

22 Other Dimensions Calibration Mistakes

FEATURES 50 YEARS OF QUALITY

30 A Look Back at Laser Measurement In this month’s edition of 50 Years of Quality, we take a look at how Quality has covered the relatively new technology of laser measurement over the years.

QUALITY MEASUREMENT

32 Don’t Leave Out Fixturing The right fixturing is the key to getting complete success and production from inspection equipment.

QUALITY TEST & INSPECTION

36 Hardness Testing Market Makes Adjustments

24 Quality 101 X-Ray Tomography: The Basics

28 Quality Innovations Microscopy Technology Results in Sharper Images

52 Case Study  Palletized Production Reduces Lead Time  Error Proofing Your Staff

60 Quality Products

The shift toward the automation of hardness testing is a strengthening trend.

64 Classifieds QUALITY SOFTWARE & ANALYSIS

40 Calibrations in the Cloud For organizations looking to upgrade or replace their current calibration system, cloud computing is an option worth investigating.

QUALITY MANAGEMENT

46 Taking Quality to the Customer Maintaining quality on customized trucks is all in a day’s work for this year’s Quality Plant of the Year winner, Daimler Trucks North America Cleveland Truck Manufacturing Plant.

IBC Advertising Index

NEXT MONTH  Quality Professional of the Year  Calibration  Digital Inspection  SPC

ABOUT THE COVER Daimler Trucks North America Cleveland Truck Manufacturing Plant builds five different class 8 Freightliner models—Argosy, Columbia, ST, Cascadia and M915A5 military. Each of these models can be ordered with different configurations based on the customer’s application. Maintaining quality has been made easier by implementing a truck operating system. Source: Daimler Trucks North America Cleveland Truck Manufacturing Plant

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March 2011 | QUALITY

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O N L I N E TA B L E O F C O N T E N T S

M A R C H 2011

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QUALILITT YMAG.COM Robot Inspection, Minus the Robot How does robotic measurement work? First, take the robot out of the equation.

The Metrotom CMM: A Unique Metrology Solution April 20, 2:00 p.m. ET

Restoring History A project manager of the restoration of one of the largest coordinate measuring machines (CMMs) in North America discusses bringing this vintage tool back to life. Installed at The Boeing Co. in 1987 and then sold for scrap, the CMM is being reworked to better-than-new condition.

SIGN UP FOR QUALITY’S E-NEWS NOW

Working Toward Six Sigma Goals Kraft Foods is working toward Six Sigma goals with new software that makes it easy to analyze Zarpac Performance Index (ZPI) data. By creating a direct link between ZPI manufacturing performance data and projects, the system eliminates the time-consuming process of manually collecting and transferring data.

CONNECT WITH QUALITY:

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

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

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

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

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Quality Leadership 100 Companies

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QUALITY | March 2011

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F RO M T H E EDI TOR

B Y GIL L IA N C A MP B E L L

In it Together M Gillian Campbell is editor of Quality Magazine. Gillian can be reached at [email protected].

We’ve introduced mobile tagging as another way for you to stay informed. Take a picture of the barcode with your smartphone to receive exclusive material from Quality. Get the free app for your phone at http://gettag.mobi

arch is always one of my favorite issues because we announce the Quality Plant of the Year. This annual award recognizes a plant that has applied world-class quality technology, equipment, services and techniques that result in reduced scrap, rework, warranty or manufacturing costs, improved productivity or cycle time, increased capacity or improved adherence to quality standards. You probably already noticed from the cover that this year’s winner is Daimler Truck North America’s Cleveland Truck Manufacturing Plant, which builds five different Freightliner models. After a few weather- and security-related delays, I finally made my way to Cleveland, NC, to visit the plant. I was greeted by Plant Manager Mike McCurry and Quality Manager Chris Harris, along with the rest of the management team. When it comes to the plant of the year, the one thing that resonates with me year after year is how engaged all of the employees are. This year’s winner is no exception. From the beginning, it was clear that this is a team that is extremely proud of the work that it does. The management team was quick to acknowledge that each of its members, from the production workers to the United Auto Workers (UAW) representative, as well as the management team, has an integral role in making the plant the best that it can be and in winning the Quality Plant of the Year award. Everyone at the plant recognizes that they’re all in it together. When you’re delivering 60 trucks every day—potentially 60 different

trucks—you have to be in it together to keep quality levels high. When customers visit the plant, the production workers aren’t afraid to ask, “How can we do it better?” Because of this enthusiasm, McCurry has said that the line employees can sell a truck just as easily as the sales team can. It doesn’t stop there. Last year the nearly 1,000 production employees submitted a staggering 12,000 ideas for improvement. Of those, approximately 85% were put into practice, most by the way of self-implementation. Like many companies, the plant was hit with layoffs due to the economy. Still, through the United Way, the employees made record donations this past holiday season. They realized that they were helping their own to have a better holiday. The employees echo the sentiment that Freightliner is the largest family business that’s not really a family business. Isn’t that the type of atmosphere you want to foster? An atmosphere where the enthusiasm is infectious and where the entire team asks, “How can I do it better?” An atmosphere where employees treat a company as their own family business? How are you empowering your employees? Share your thoughts with me at campbellg@bnpmedia. com, 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.

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INDUSTRYNEWS | Business News | Coming Events | People News | Mergers |

COMING EVENTS APRIL 5-7 AERO DEF Anaheim, CA SME (800) 733-3976 aerodef.sme.org 11-13 QUALITY CONFERENCE Charlotte, NC Quality Magazine (888) 530-6714 www.qualitymagconference.com 19-21 FUNDAMENTALS OF RANDOM VIBRATION AND SHOCK Testing College Park, MD Equipment Reliability Institute (805) 564-1260 www.equipmentreliability.com vibration_course1.html

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QUALITY | March 2011

SME SELECTS 2011 PRESIDENT AND BOARD OF DIRECTORS

apprenticing with Peterson in 1980 to his current role of professional engineer and managing director. DEARBORN, MI—Reaching beyond Throughout Bradley’s more than two the North American borders for decades with the society, he’s the first time, the Society of held a number of leadership Manufacturing Engineers (SME) roles, including terms on the has elected Paul D. Bradley, PE, SME Executive Committee managing director, Peterson and Board of Directors and Industries (Adelaide, South the Ad Hoc International Australia), as its 2011 president. Strategies Committee. He was Bradley was sworn in—along nominated as an international with the rest of the 2011 SME representative on the SME Executive Committee and Board Paul Bradley Region Chairs Committee and of Directors—at the Society’s twice as chair of the Adelaide No. 169. Awards and Installation Banquet in He also is a recipient of the 1997 SME Dearborn, MI. Ralph E. Cross Outstanding Young As president, Bradley will lead the Manufacturing Engineer Award. board in developing the SME Strategic Bradley also served as a memPlan 2015 and plans to strengthen the ber of the Board Work Group on Society’s brand. International Alliances, which devel“I have a strong belief in nurturing oped key recommendations leading the brand,” Bradley tells Quality. “It’s to a new alliance with the Australian all about the brand. I have recently Manufacturing Technology Institute established an SME brand task force Ltd. (AMTIL). In 2001, he received consisting of high caliber members to the South Australian Governor’s address high level charges relating to Leadership Foundation Fellowship our brand goal.” Award. Bradley completed a four-year Bradley credits the support of his apprenticeship as a fitter and turner boss Gwen Peterson and his mentor, the and is a registered professional engilate Max Peterson, for encouraging his neer in South Australia. He earned interest in the engineering profession a diploma of management from by inviting him to join the former SME O’Halloran Hill College. Adelaide No. 169 chapter back in 1989. “I had a thirst for knowledge, and I still have a thirst for knowledge,” MEMA NAMES INDUSTRY Bradley says. “And SME offers more CHAMPION AWARD RECIPIENTS manufacturing knowledge than anyone WASHINGTON, DC—Bob McKencould absorb.” na, president and CEO of the Motor Bradley’s career path gives him & Equipment Manufacturers Assoa broad view of manufacturing— ciation (MEMA), announced that

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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Sen. Debbie Stabenow (D-Mich.) and Rep. Geoff Davis (R-Ky.) were chosen as this year’s recipients of the Joseph M. Magliochetti Industry Champion Award, a special recognition given to elected officials who have shown outstanding leadership on behalf of motor vehicle parts manufacturers. The Industry Champion Award is given each year in the memory of Joseph M. Magliochetti, a former MEMA chairman who also served as the chairman and CEO of Dana Corp. until his death in 2003. Stabenow and Davis received the award at MEMA’s Legislative Summit in March. “We are very pleased to honor two distinguished public servants with this prestigious award,” says McKenna.

“Both Sen. Stabenow and Rep. Davis are keenly aware of the significance of parts suppliers to the economies of their communities and the whole nation. Their leadership on key supplier issues and willingness to help educate colleagues on the contributions of the supplier industry make them very worthy recipients.” McKenna specifically mentioned Stabenow’s leadership on the Advanced Vehicle Technology Act in the Senate; her work to address needed changes in the Sec. 136 loan program to make it more accessible to suppliers and extending it to medium- and heavy-duty technology; her leadership on the Commercial Motor Vehicle Advanced Safety Technology Tax Act; and her steadfast support of R&D tax credit bills.

FORD TO HIRE 7,000 WORKERS DEARBORN, MI—Ford Motor Co. will add more than 7,000 workers in the United States over the next two years, the company says. This includes positions for 750 engineers with proficiency in batteries and other advanced technology, as Ford begins producing several new vehicles. The company plans to hire 4,000 manufacturing workers this year, it says. Approximately 50% of those employees will be at the Louisville, KY, assembly plant to produce the new Ford Escape. It expects to add at least 2,500 new manufacturing jobs in 2012. The company recruited workers in Detroit and other cities, including San Jose, CA, and Raleigh and Durham, NC. The 750 engineers that Ford plans to hire will work on hybrid and electric

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vehicles. Ford introduced three future electric and hybrid vehicles at the Detroit auto show, including an electric version of the Ford Focus, which will go on sale in the United States later this year and hybrid and plug-in hybrid versions of the C-Max minivan, which will go on sale in 2012. The company also said it plans to hire 6,500 U.S. manufacturing workers over the next two years as it ramps up production of new vehicles. Ford had

already announced some of its new hires, including the 1,800 workers being hired to make the new Ford Escape at Kentucky’s Louisville assembly plant starting late this year. Some of the workers will be new to Ford, although some will be come from other U.S. plants where Ford has laid off workers. It was not clear whether any of the newly announced jobs would be at the Chicago assembly plant. After an

announcement last summer, Ford added a second shift at the Torrence Avenue plant, adding 1,200 workers— about 400 to 600 of them new—to produce the 2011 Ford Explorer SUV.

JANURAY PMA BUSINESS CONDITIONS: OPTIMISM ON THE RISE CLEVELAND, OH—According to the January 2011 Precision Metalforming

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QUALITY | March 2011

The National Association of Manufacturers (NAM, Washington, DC) has named Jay Timmons president and CEO. Timmons has served as executive vice president at NAM and will succeed former Michigan Governor John Engler in this position. Timmons has extensive experience in government relations, public affairs, political campaigns and business. The Precision Metalforming Association (PMA, Cleveland, OH) has elected Augusto Gil to the position of metal spinning division vice chair and Benjamin Barnett to the next generation leaders division vice chair. Gil, general manager for Hialeah Metal Spinning (Hialeah, FL), has been active within the Metal Spinning Division for nearly a decade and previously served as a member of the group’s program committee. Barnett, vice president of Principal Manufacturing Corp. (Broadview, IL), has been participating in division activities for the past several years and serves as the membership chair for the local PMA Chicago District. This year, the American Society of Safety Engineers (ASSE, Des Plaines, IL) will celebrate its 100th anniversary. Today, ASSE has more than 32,000 occupational safety, health and environmental practitioner members located worldwide with 151 chapters, 35 sections and 60 student sections. To celebrate its centennial, ASSE will debut a documentary on the history of safety and ASSE and an updated Professional Safety journal. Additionally, ASSE is preparing for its professional development conference and exposition: Safety 2011, to be held in Chicago at the McCormick Place Convention Center June 12-15, 2011.

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Association (PMA) Business Conditions Report, metalforming companies are optimistic about business conditions during the next three months. Conducted monthly, the report is an economic indicator for manufacturing, sampling 119 metalforming companies in the United States and Canada. The January report shows that 47% of participants forecast an improvement in economic activity (up from 40% in December), 43% predict that activity will remain unchanged (compared to 46% last month) and 10% report that activity will decline (down from 14% in December). Metalforming companies also expect improvement in incoming orders. Fifty-two percent of participants predict an increase in orders (up from 44% in December), 36% anticipate no change (compared to 40% last month) and 12% predict a decrease in orders (down from 16% in December). The percentage of metalforming companies with a portion of their workforce on short time or layoff decreased to 12% in January from 16% in December. The number is at its lowest level since October 2007, when only 8% of companies had workers on short time or layoff, and is much lower than one year ago, when 52% reported employees on short time or layoff in January 2010. “In spite of a modest year-end softening in orders, metalforming companies experienced significantly improved business conditions in 2010 and anticipate continued growth in 2011,” says William E. Gaskin, PMA president. “On average, for the first 11 months of 2010, metalforming companies reported a 41% increase in orders and a 37% increase in shipments compared to 2009.” PMA is the full-service trade association representing the $113-billion metalforming industry of North America—the industry that creates precision metal products using stamping, fabricating, spinning, slide forming and roll forming technologies, and other value-added processes.

While hybrid vehicles have won four times in the 18 years that the awards have been given, this was the first win for a vehicle that can move a meaningful distance on electric power alone. The winners were chosen by a jury of 49 automotive journalists from the United States and Canada. The awards are unique in the United States because instead of being given by a single media outlet they are awarded by a coalition

of automotive journalists from the United States and Canada who represent magazines, television, radio, newspapers and Web sites. The awards are designed to recognize the most outstanding new vehicles of the year. These vehicles are benchmarks in their segments based on factors including innovation, design, safety, handling, driver satisfaction and value for the dollar.

38DL PLUS Ultrasonic Thickness Gage Advanced Features, Simple Operation The 38DL PLUS is an innovative, versatile thickness gage for applications ranging from internally corroded pipes to very thin or thick plastics, metals, composites, rubber, and glass. • A full line of dual and single element transducers - Dual element for corrosion measurements - Single element (0.5 MHz to 30 MHz) for thin or difficult to penetrate materials • Rugged, designed for IP67 rating • Vibrant full VGA display • Wide thickness range: 0.08 mm (0.003 in.) to 635 mm (25 in.)* • THRU-COAT® and Echo-to-Echo avoid paint removal • Internal Oxide/Scale software option • V-Path Builder for better precision when using non-standard transducers

CHEVROLET, FORD WIN NORTH AMERICAN AUTO AWARDS DETROIT—The Chevrolet Volt is the 2011 North American Car of the Year and the Ford Explorer is the 2011 North American Truck of the Year.

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* depending on material and transducer selection

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It is the fourth time General Motors has won the North American Car of the Year. Most recently, the Chevrolet Malibu was the 2008 North American Car of the Year. It was the second year in a row that a Ford was named the North American Truck of the Year. Last year the winner was the Transit Connect. It also is the seventh time a Ford has been the North American Truck of the Year, a category it has dominated.

The Volt won with 233 points, followed by the Hyundai Sonata with 163 and the Nissan Leaf electric with 94. The Explorer won with 253 points while the Jeep had 138 and the Durango 99. During the 18 years of the awards: • Domestic automakers have won North American Car of the Year 10 times. European automakers have won four times, Japanese automak-

PEOPLE NEWS Northwire Technical Cable (Osceola, WI), a technical and retractile cables and cable assemblies company, has presented its Ormund A. Kravik Award to 35-year team member and industry Harold Gjerning veteran Harold Gjerning. The award, named for company founder Ormund A. Kravik, recognizes work ethic, commitment to quality, ingenuity, innovation, integrity, meticulousness, engineering acumen, an entrepreneurial spirit and a comprehensive solution-oriented approach to problem solving. Gjerning was nominated by his Northwire peers for the award. Automated Precision Inc. (Rockville, MD) has appointed Joe Bioty as COO. Bioty has worked in high-technology businesses for more than 40 years and led API as COO from 2003 Joe Bioty to 2007. Prior to joining API, Bioty was president and CEO of AMT Machine Systems, a Columbus, OH-based robotic components and systems manufacturer. Bioty also has held executive positions at M&M Precision Systems and General Electric, and founded NorthStar Technologies in 1990 before selling it to Danaher Corp. in 2001. Boeing (Chicago) has named Kim Hammonds chief information officer and vice president of the company’s information technology (IT) organization. Hammonds, who was formerly vice president of the Boeing IT infrastructure organization, replaces John Hinshaw, who has been named vice president and general manager of Boeing’s new information solutions division in Boeing defense, space and security divisions. EPIC Systems Inc. (St. Louis) has appointed Maria L. Holt to the role of business development coordinator. Holt holds a Bachelor of Science degree in business management from the University of Missouri, from Maria L. Holt which she graduated Magna Cum Laude in May. Holt is responsible for the development, execution and follow-up of business development activities including:

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e-mail marketing campaigns, marketing research and analysis, social media, Web site development, new lead development and follow through, and contact management. Michael W. Riehn has Michael W. Riehn been appointed to the role of marketing director. Riehn brings approximately 10 years of industrial marketing, Web and advertising experience to EPIC’s turnkey engineering and fabrication systems. Riehn is responsible for the creation, development and management of all marketing, sales promotions and public relations. Laboratory Testing Inc. (LTI, Hatfield, PA) has appointed three employees to the role of supervisor at its testing and calibration laboratory: Sherri Scheifele has been assigned supervisory responsibilities in Sherri Scheifele the quality assurance (QA) department at LTI. She has been with the company for 20 years, and has held the position of QA specialist for the past five years. She will continue to assist with audits, maintain the quality policies and manuals, and assist customers with quality matters. Mike Hiller has been with LTI since 2007 as a field technician in the calibration department. With his promotion to field supervisor, Hiller will supervise and train field technicians and introduce electrical and temperature calibration Mike Hiller services to customers. Mike Sagel joined LTI as an information technology administrator in 2008. Sagel will continue to maintain the computer network hardware and software and the phone system, while assuming Mike Sagel supervisory responsibilities. IPG Photonics Corp. (Oxford, MA) has appointed Chris Pilcher to the role of sales manager of its Canada location. Pilcher brings more than 25 years of experience in the industrial laser industry to the position. Pilcher has experience selling industrial lasers and systems to original equipment manufacturers, integrators and end-users. www.qualitymag.com

ers have won three times. A Korean automaker has won once. • Domestic automakers have won North American Truck of the Year 12 times. Japanese automakers have won four times. European automakers have won twice.

ALLIED VISION TECHNOLOGIES ACQUIRES VDS VOSSKÜHLER Stadtroda, Germany—Allied Vision

Technologies, producer of digital industrial cameras with Gigabit Ethernet and FireWire interfaces, has acquired 100% of the shares of the camera producer VDS Vosskühler (Osnabrück, Germany). Effective immediately, the acquisition increases AVT’s portfolio by the addition of near infrared and long wave Infrared camera technologies, as well as extensive competencies in the area of active camera cooling.

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BUSINESS NEWS Magnetic Products Inc. (MPI, Highland, MI), a worldwide provider of both magnetic and nonmagnetic material handling solutions, will celebrate its 30th anniversary in 2011. Since starting operations, MPI has delivered services centered on the development, engineering and building of inventive magnetic and other forms of material handling equipment used in a host of different industries worldwide. MPI says its commitment to customer education on the practical use and application of magnets and metal detection technologies and advancement of inventive magnetic and other types of material handling equipment is accomplished through significant investments in research and development and proactive product training. Framos Electronics (Munich, Germany), a supplier of image processing systems, and Smartek, a Croatian electronics company, have reached an agreement to work together more closely. The relevant contracts were signed at the Electronica Trade Fair in Munich 2010. “Thanks to our partnership with Smartek, we are continuing our tradition of offering European customers within the image sensor industry a marketing platform and making use of our global storage and logistic services,” says Managing Director of the Framos Group Andreas Franz. Geomagic (Research Triangle Park, NC) announced a new agreement with 3D3 Solutions as a reseller of the company’s 3-D scan data processing software. 3D3 Solutions is a developer of 3-D scanning and visualization technologies. When used in conjunction with Geomagic software, users have the ability to edit, process and optimize the 3-D scan data for use in downstream applications making it particularly useful for manufacturing, design and analysis. TÜV SÜD Canada (Toronto, Canada), part of the global TÜV SÜD testing and certification organization, has acquired Innovative Testing Solutions (ITS, Newmarket, Ontario). ITS is a diversified and experienced testing laboratory, with ISO/IEC 17025 A2LA accreditation, and provides testing of batteries and electrical components, along with environmental and mechanical life cycle testing. The acquisition of ITS further strengthens TÜV SÜD’s presence and testing capabilities in the North American market. Instron (Norwood, MA), a provider of testing equipment solutions designed to evaluate mechanical properties of materials and components, has announced that its calibration laboratory has achieved renewal of its ISO/IEC 17025 accreditation upon completing a three-day re-accreditation assessment by the National Voluntary Laboratory Accreditation Program (NVLAP), a program administered by the National Institute of Standards and Technology (NIST), the National Metrology Institute (NMI) of the United States. Pfeiffer Vacuum Technology AG (Asslar, Germany) closed the acquisition of Alcatel-Lucent’s Vacuum Technology Unit, Adixen. The company had announced the intention to purchase Adixen on Nov. 3, 2010. The purchase price totals approximately $2.7 million on a debt/cash-free basis. In order to finance the deal,

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QUALITY | March 2011

Pfeiffer Vacuum had generated about $1.5 million through a capital increase and sale of treasury shares on November 18. The remaining part of the purchase price was funded through a bank loan. Calibration services company Trescal (Rungus Cedex, France) is continuing its international expansion with the acquisition of Dynamic Technology Inc. (DTI, Detroit), a principal service provider. The transaction will allow Trescal to enter the U.S. market and become a larger global provider of metrology services. Founded in 1987, DTI employs 180 staff in Detroit, Chicago, Cleveland, Dallas and Houston. Specialized Technology Resources Inc. (STR, Enfield, CT) has acquired the remaining membership interests of STR-Registrar LLC (STR-R), making it a wholly owned subsidiary of the company. STR has owned 51% of STR-R, an accredited international provider of management system certification and registration services, since 2001. This acquisition is part of STR’s strategy to continue to invest in its consumer products quality assurance business. Methods Machine Tools (Sudbury, MA), a supplier of machine tools, automation and machine tool accessories for more than 50 years, is expanding its Elgin Tech Center in response to Methods’ success at IMTS in September 2010. Methods sold more than 50 machines at IMTS, including almost all of the machines on display in its booth. Application engineers and service personnel are also being added to the Elgin facility to meet the increasing demand for Methods’ brands. Natvar (City of Industry, CA), a Tekni-Plex company and global extruder of medical tubing used in surgical procedures and related medical applications, has received ISO 9001: 2008 certification at its Clayton, NC, facility in recognition of its standardized best practice production techniques. The company’s City of Industry, CA, location earned its ISO certification in 1996. The company has undertaken extensive preparations for the ISO Certification process since June 2009. Industrias Romi SA (São Paulo, Brazil), the parent company of Romi Machine Tools (Erlanger, KY), has reached a milestone in its 80-year history: shipping its 150,000th machine. A vertical machining center called Romi D800 was delivered in the presence of Romi directors and employees, and representatives of customer ZHS Industria e Comercio Ltda., of Brazil and BNDES, the bank that financed the purchase. Jetcam (Monaco) celebrates its 25th anniversary this year. The company was founded in Australia, relocated to Germany in 1990 and then to the South of France in 1993. In 1999 JETCAM acquired U.K.-based software developers Camtek Ltd., but became a privately owned company again in 2005. The following year JETCAM sold Camtek to Vero Software Ltd. Since 1986, the company has grown to be a dominant force in the CADCAM and nesting market, with more than 7,000 licenses spanning 70 countries.

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CURRENT SPONSORS:

Quality Magazine is proud to collaborate with UNC-Charlotte and the Charlotte Research Institute for the 2011 Quality Conference. As part of this collaboration UNC-Charlotte will kick off the event by hosting the Monday conference workshops and welcome reception including a tour of their metrology lab. The University of North Carolina at Charlotte is the home of the world’s premier university metrology lab. Located on the University’s Charlotte Research Institute Campus, the Metrology Lab is one of the core facilities of the Center for Precision Metrology. The lab is central to the education and research efforts in the areas of precision engineering and metrology at UNC-Charlotte, and with the wide variety of high-end measurement instruments, provides measurement services to the University community and local industry.

..you position your company as an industry leader by the Quality Conference. Embassy Suites Charlotte-Concord Hotel SPECIAL DISCOUNTED ROOM RATES HAVE BEEN SECURED FOR CONFERENCE PARTICIPANTS. For overnight accommodations please contact the Embassy Suites Charlotte-Concord Hotel directly at 1-704-455-8200 or 1-800-EMBASSY. Mention “Quality Conference” or “QUA” to receive the discounted group rate of $149/night + tax. Reservations must be made by March 11, 2011, to guarantee discounted pricing and availability.

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www.qualitymagconference.com Joe Gibbs Racing Tour SOLD OUT!

Monday, April 11, 2011 11:00am-2:00pm

Tour @ Joe Gibbs Racing Joe Gibbs Racing (JGR) is one of the premier organizations in NASCAR, currently fielding three NASCAR Sprint Cup Series teams, two NASCAR Nationwide Series teams and a driver development program that includes two full-time NASCAR East Series teams. The Joe Gibbs Racing Tour will give attendees a sneak peak on how race cars are built from the ground up and prepared for each race track. Departments included in tour will consist of fabrication, paint and body, advanced technology center, quality control and final preparation. WORKSHOP 1

WORKSHOP 2

2:00pm- 5:00pm

The Secrets of Thread Gaging David Harris, Glastonbury Southern Gage

Measurement Uncertainty - What It Is, Why It Occurs and How to Accommodate It Henry Alexander, Perry Johnson Laboratory Accreditation Inc.

5:00pm-6:30pm

Welcome Reception and Metrology Lab Tour at UNC-Charlotte

*workshops will be held at UNC-Charlotte

Tuesday, April 12, 2011 7:30am-8:30am

Continental Breakfast and Registration

8:30am-8:45am

Welcome Address Darrell Dal Pozzo, Quality Magazine

8:45am-9:30am

KEYNOTE: The GD&T Measurement Conundrum Jim Salsbury, Mitutoyo America Corporation We all want to measure “right,” but sometimes measuring “wrong” is the best decision to make. Modern measuring equipment and sophisticated software provide significant benefits in versatility and automation, but with great flexibility comes great responsibility in implementation. Equipment like coordinate measuring machines (CMMs) provide seemingly endless options for any specific measuring task. The CMM user needs to understand design intent (GD&T), software options and their machine limitations to determine the optimal measuring approach. In many cases, the “theoretically correct” method does not provide the best overall solution. This presentation will use a variety of measurement examples to highlight the GD&T Measurement Conundrum and present best practice strategies when using modern measuring instruments.

9:30am-10:15am

Quality Plant of the Year Award Presentation Mike McCurry, Daimler Trucks North America

10:15am-10:45am

Morning Break TRACK 1

TRACK 2

10:45am-11:30am

Developing a Risk-Based Calibration Program Harry Spinks, Boston Scientific

Industrial CT Scanning Stephanie Masse, Jesse Garant & Associates

11:30am-12:15pm

How to Calibrate Any Machine Tool David Maxham, Automated Precision Inc.

X-Ray Micro CT: The Rules and When to Break Them Andrew Ramsey, Nikon Metrology Inc.

12:15pm-1:30pm

Luncheon

1:30pm-2:15pm

PCMM Certification Progress Alan Metzel, Nothrop Grumman

X-Ray Computed Tomography for 3-D Inspection Jeff Bibee, Werth Inc.

2:15pm-3:00pm

CMM Based Surface Profilometry of Macro and Micro-Parts Shane Woody, InSituTec

Using Strain Signatures to Detect Process Changes Paul Hogendoorn, OES Inc.

3:00pm-3:30pm

Afternoon Break

2011 SCHEDULE 3:30pm-4:15pm

Verifying the Accuracy of CMMs Between Calibrations Rick Richardson, QA Productivity Systems

Can Smart Automated Weld Inspection Turn A Cost Into A Profit? Jeffrey Noruk, Servo Robot Corp.

4:15pm-5:00pm

Would Statistical Process Control Work for Me? Rick Sloop, InfinityQS International

Advances in Eddy Current Verification of Heat Treat Processes Joe Jessop, Criterion NDT

5:00pm-6:30pm

Networking Reception

Wednesday, April 13, 2011 7:30am- 8:30am

Continental Breakfast and Registration

8:30am-8:45am

Opening Remarks Darrell Dal Pozzo, Quality Magazine

8:45am-9:30am

KEYNOTE: No-Compromise Leadership – A Higher Standard of Leadership Thinking and Behavior Neil Ducoff, No-Compromise Leadership No-Compromise Leadership is all about the thinking, behavior and accountability that support all leadership results and outcomes. Joined together, these two simple words immediately establish a higher standard of leadership thinking and behavior. They provide a powerful internal compass that keeps you and your company steadfastly on course. By design, no compromise cuts through myriad excuses, emotional blockages and procrastination that silently infect leadership performance. When no compromise becomes your mandate - the guiding principle upon which all other leadership behavior emanates - the resulting business outcomes will be nothing short of breakthrough.

9:30am-10:15am

Quality Professional of the Year Award Presentation Forrest Breyfogle, Smarter Solutions Inc.

10:15am-10:45am

Morning Break TRACK 1

TRACK 2

10:45am-11:30am

Hand Gages and Metrology Challenges for Manufacturing in the 21st Century Paulo Pereira, Caterpillar Inc.

Smart Cameras and Technology Gains Driving its Adoption Narayan Subramaniam, Cognex

11:30am-12:15pm

The Metrology of Golf Pat Nugent, Mahr Federal

Optical Measuring Technologies for Air Quality and Regulatory Compliance James Drago, Garlock Sealing Tech.

12:15pm-1:30pm

Luncheon

1:30pm-2:15pm

Noncontact Metrology: Eliminating the Cycle Time, Data Density & Price Trade-Off Paul Joss, Perceptron

Inspection Applications of Acoustic Pulse Reflectometry (APR) Dr. Noam Amir, AcousticEye

2:15pm-3:00pm

Total Quality Management is NOT Total! Walter McGee, Raytheon Space & Airborne Systems

Accuracy, Efficiency, and other Technology Advancements for Common and Complex Coating Thickness Measurement Applications Paul Lomax, Fischer Technology

3:00pm-3:30pm

Afternoon Break

3:30pm-4:15pm

KEYNOTE: Beyond Quality – A Roadmap for Innovation Praveen Gupta, Accelper Consulting There are many tools and techniques to assure the quality of your product. If you learn enough and research enough, you’ll find what best fits in your organization. But, if you don’t have people willing to use these tools, people willing to find better ways to do their job, people looking and thinking how to do their job “error proofing,” the journey to Zero Defects will be very difficult. You’ll need to have engineers analyzing every single process to design a Poka Yoke. During this presentation, you’ll be able to see how a company created an environment where every employee implements a change/improvement in his process/activity to make a quality product.

4:15pm-4:30pm

Closing Remarks Darrell Dal Pozzo, Quality Magazine

FAC E OF QUALI T Y

B Y J IM L . SMI T H

A Tribute to Dr. Joseph M. Juran Arguably the greatest management and quality consultant of the 20th century, Dr. Juran is remembered as an evangelist for quality and quality management. 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].

N

ear the anniversary of the death of Dr. Joseph M. Juran (1904–2008), I thought it might be of interest to revisit the person who has been called the father of quality and referred to as the greatest quality giant of the 20th century. Perhaps more importantly, he is recognized as the person who influenced the adding of the human dimension to quality, broadening it from its statistical origin to the more comprehensive total quality management. Juran pushed for the education and training of managers. His thought was that human relations problems were most important to isolate and resolve. He felt that resistance to change was more of a cultural issue and the root cause of quality problems. My personal exposure to Juran began with an article of his I read more than 35 years ago. As a young quality engineer, I was part of team charged with bringing to my company unique quality approaches. Juran consented to visit with our senior management to share his thoughts. I was able to meet him on several occasions, but during our first meeting, I was already inspired to join the American Society for Quality and get involved in quality. Through a journey of studying and learning about quality from many people, I became a Juranite—a disciple of his theories and practioner of his principles of quality. He didn’t just teach statistics. In fact, he didn’t think of himself as a statistician but simply dedicated to the total quality approach. Through Juran’s influence, it became evident that the human side of quality was just as important as the technical side. Juran’s life is like a Horatio Alger story. His humble start in life gave no indication to the success and notoriety he would achieve. In 1924, he accepted a position in the inspection group at Western Electric in Hawthorne, IL, at a weekly salary of $27. He rose to inspection division chief in just five years. During this time, he wrote the first known text on statistical quality control— and the ancestor of today’s widely-used Western Electric Statistical Quality Control Handbook.

Through Dr Juran’s influence, it became evident that the human side of quality was just as important as the technical side.

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QUALITY | March 2011

Little did he know at the time, the decision to work at Western Electric would set him off on a more than 75-plus year career in quality. He would work with a virtual who’s who in quality. People such as George Edwards, Harold Dodge, Harry Romig and Walter Shewhart helped shape his ideas and his future. During WWII, Juran served the Department of Defense as assistant administrator of the Lend-Lease program. After the war, he didn’t go back to Western Electric but went forward to create history. In 1946, he, along with several other notables, founded the American Society for Quality Control. Juran developed what arguably became the foremost influential course on quality. His “Managing for Quality” curriculum has been taught to thousands of people in almost every country of the world. In 1954, he conducted seminars for Japan’s senior and middle managers, explaining the roles they had to play in promoting quality. Juran was invited back many times and his teachings were so inspirational that a temple was named in his honor. He also was honored with Japan’s highest award that can be given to a non-Japanese—the Order of the Sacred Treasure. It was awarded in recognition of his contribution to “the development of quality control in Japan and the facilitation of U.S. and Japanese friendship.” Juran’s process of developing ideas was gradual. Top management involvement, the Pareto principle—which could easily have been named the Juran principle—the need for widespread quality training, the definition of quality, the Juran Trilogy, the project-by-project approach to improvement— these are some of the ideas for which he is best known and all emerged gradually. The first edition of his classic book, the Quality Control Handbook, first released in 1951, contained about 100 pages and the fifth edition more than 1,900 pages. The sixth edition has recently been released and he edited it even in the final days of his life. His handbook is still widely considered to be the bible on quality. Juran’s groundbreaking work in quality management and leadership was the catalyst that transformed industries. Shortly before his death, Juran said, “My job of contributing to the welfare of my fellow man is my great unfinished business.”

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OTHE R DI MENSI ONS

B Y H IL L C OX

Calibration Mistakes Take a closer look at common mistakes made in regards to calibration.

Hill Cox is president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

N

o matter how careful we are at any given task, mistakes often are made; the calibration of gages and instruments is no exception. Sometimes the mistakes are hidden by a quantity of repeatable numbers. At other times, the fact that two or more laboratories offer the same calibrated values is used as proof that the numbers are good when both could be making the same mistake. While it will be assumed that newcomers to the calibration field are the greatest source of such problems, this assumption itself is a mistake. Many experienced hands in the game are prone to making mistakes as well, but because they’ve been at it for so long, it is assumed they know what they are doing. There is a lot of “how to do it” literature out there but little “how not to do it” information—a void I’ll attempt to fill in the next few columns. Where will the information come from to fill this gap in our knowledge? Mistakes made by others—a very reliable source. Equipment makers and experienced calibration laboratories encounter these mistakes all the time, particularly in the heat of battle over measurements. This column will deal with some general mistakes, while future columns will look at mistakes often encountered in the calibration of specific gages and instruments. • Skills. Too many companies assume that if someone knows how to use a particular device, they’re skilled enough to calibrate it. While some instruments lend themselves to this type of thinking, it doesn’t hold up for other equipment as will be shown in upcoming columns. • Environment. When it comes to calibration, we have to deal with the climate in which the work is done. Unfortunately, the overall or ambient temperature of the laboratory becomes the point of focus when the focus should be on the instruments, masters and item being calibrated. • Specifications. Many items, particularly fixed limit gages, are made to rather detailed specifications, copies of which should be on hand for each type calibrated. Too often, laboratories do

Too many companies assume that if someone knows how to use a particular device, they’re skilled enough to calibrate it.

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QUALITY | March 2011

not want to spend the money on the specifications, and thereby calibrate things they don’t need to, use procedures that conflict with them or fail to measure features that can have a dramatic impact on the results. Many companies purchase software to avoid buying the standards, but in the real world, at this time, the printed specification is the law— not the software. And there can be significant differences between the two. In a similar vein, some folks rely on a general purpose handbook for such information. In both cases, either source could be out of date since the source documents are usually reviewed every five years. Another mistake made by calibration facilities is to use the markings on gage handles as the “standard” to which they are calibrated. They can be in error in some cases, or where foreign specifications are involved, may be marked with product dimensions, not gage dimensions. • Equipment. Many everyday measurements can be made using more than one instrument type, but when it comes to calibration, the choices are limited. If you don’t have the right equipment for calibration, you won’t get anywhere close to the right measurements. This means your trusty digital micrometer or indicator with 50-microinch or 0.001-millimeter resolution won’t cut it. If either one had working accuracy close to their resolution, laboratories would not spend thousands of dollars for equipment to do what appears on the surface as a simple measurement. • Traceability. For measurements to have any validity, they have to be traceable to the national standard. When high accuracy is required, as is the case with gage and instrument calibration, this traceability cannot start several steps down the food chain. The higher the level of accuracy required, the closer you have to get to the national standard, for example, NIST. At the highest level for a commercial facility this means their primary standards—and some working standards—have to be calibrated directly by NIST. You can plot and scheme all you want, but if you’re serious about calibration, this requirement cannot be ignored.

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Q UAL I T Y 101

 Modern developments in computer tomography now provide high precision measurements, even on internal features, using X-ray technology. Source: Werth Inc.

3-D COMPUTER TOMOGRAPHY Unlike X-ray machines of the past, accurate tomography starts with machine construction. A granite base provides the foundation for precision slides and scales from coordinate measuring machine design. The base includes a high-precision rotary axis, which can include an additional axis for a multisensor approach for the highest accuracy.

X-Ray

Tomography: The Basics By building on the technology that was developed for optical and multisensor measurement, it is now possible to incorporate X-ray as a sensor for precision measurement. B Y JEFF B IB E E

X

-ray technology has existed for some time in the industry but until recently one could not dimensionally measure the parts. Modern developments in computer tomography (CT) now provide high precision measurements, even on internal features, using X-ray technology. The advent of this technology opens up new possibilities for verification of advanced manufacturing methods.

2-D OPTICAL MEASUREMENT In 2-D optical measurement, positions of the parts’ edges are accurately located in relation to a datum. Edges are detected using a lens to magnify and project the part image onto a charged coupled device (CCD) chip with a pixel array. The light intensity that strikes each pixel produces electronic signals called gray scale values.

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QUALITY | March 2011

Intense light, where the part does not block the light, produces high values. No light produces low values. Software evaluates where the pixel values dramatically change and establishes the locations of the edges. Algorithms compute the dimensional and spatial relationships of geometric elements to extract the part dimensions. Concepts such as optical systems, subpixeling calculations, filtering, importance of lighting schemes, variable magnification for higher accuracy and other techniques were developed to overcome inherent errors in optical measurement. Without them, optical measurement is neither accurate and traceable nor consistent. Likewise, complex technical approaches were developed to provide X-ray with accuracy. However, these 2-D basics provide a starting point to understand 3-D X-ray measurement.

GATHERING THE DATA: POINT CLOUD RECONSTRUCTION To gather data for point cloud reconstruction, the workpiece is placed on a high precision rotary axis between the X-ray tube and detector. The part is X-rayed and an X-ray projection is stored. The part is then rotated slightly and another X-ray is taken, and so on until the part is rotated through a complete 360 degrees with, typically, 400 or 800 X-ray projections. Software reconstructs these images with a known rotation angle into a voxel volume. A voxel (from volumetric pixel) is like a 3-D pixel. Instead of gray-scale light values, voxels represent density values inversely corresponding to the X-ray energy the workpiece absorbs. Evaluating where the voxel densities radically change determines the point locations on the inner and outer skins of the part. The use of calibrated grayscale algorithms provides subvoxel resolution and accuracy for the measurement points. Connecting those points with triangles produces a stereolithography (STL) view, resembling a computer aided design (CAD) model view but representing the actual part.

COMPARISON WITH CAD DATA Results of CT are nothing like the 2-D X-ray images seen at the dentist. 3-D point clouds are captured to accurately define the contours of the parts with extreme point density. With touch probes or other traditional sensors, several points are collected and geo-

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metric elements are calculated from them such as lines, planes and circles. With dense 3-D point clouds, it is not necessary to select individual points for such calculations. To assign the points to the geometrical elements to which they belong, the point cloud is merged with the CAD model by a 3-D algorithm called BestFit. A color-coded deviation plot graphically displays the distance of each actual point from the nominal surface on the CAD model. It clearly indicates where the actual part is in and out of tolerance and by how much. This can be used, for example, to correct plastic injection molds.

Workpieces absorb low energy X-ray beams and higher energy beams at different rates depending on material thickness. This results in beam hardening artifacts. This effect is partially reduced but not overcome with filters on the X-ray emitter. By limiting the spectrum of X-rays allowed to penetrate the part, more uni-

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The focal point size of the X-ray beam and the number of pixels of the X-ray sensor limit the resolution of computer tomography. Raster or grid scanning developed for 2-D optical measurement and applied to 3-D tomography provides the ability to capture large parts at higher resolution. High magnification, with its smaller field of view, scans sections of parts at a higher resolution. Precision machine design accurately repositions the workpiece and software developments precisely stitch the sections together into an accurate, complete 3-D point cloud making this possible.

As with optical measurement, physical X-ray effects must be understood and correctly compensated for accurate measurement.

Fairly high accuracy levels are achieved in computer tomography using the technology thus far explained. Further refinement in

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DIMENSIONAL MEASUREMENT Dimensional measurements are extracted by selecting patches on the CAD model and using standard coordinate measuring machine software to measure them as geometric elements. The software uses all the points assigned to the corresponding patch of the CAD model to calculate the dimensions of the geometric elements and the related features. For example, the position, vector, diameter and form deviation are extracted by selecting the patches and therefore the related points from the point cloud to measure a cylinder.

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March 2011 | QUALITY

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|

QUA LIT Y 101

| AutoCorrection

Beam-Hardening

Correction of the X-ray point cloud using a correction point cloud taken from the first article with a more accurate sensor. Source: Werth Inc.

Workpieces absorb low energy X-ray beams and higher energy beams at different rates depending on material thickness. This results in so-called beam hardening artifacts. Source: Werth Inc.

accuracy is achieved with a multisensor approach. A more accurate sensor, used on the first article only, captures an even more accurate point cloud. This more accurate point cloud, taken from the geometry of the actual part type and the X-ray point cloud is used to calculate a correction matrix. This correction matrix can be applied to all parts of the same type to fine

tune the accuracy of the final 3-D point cloud. The geometries and tolerances of some parts make this essential to achieve the accuracies required. By building on the technology that was developed for optical and multisensor measurement, it is now possible to incorporate X-ray as a sensor for precision measurement. Advances in computer technology to rapidly process

large amounts of data and new software developments open the door for this new technology. It will lead to new possibilities to reduce verification costs and meet the needs of manufacturing innovations. Jeff Bibee is vice president of sales and marketing at Werth Inc. (Old Saybrook, CT). For more information, call (860) 399-244, e-mail jeff. [email protected] or visit www.werthinc.com.

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

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QUALITY | March 2011

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Q UA L I T Y I NNOVAT I ONS

 The AcuityXR is available as a capability on select models of the ControuGTTM family of noncontact, 3-D optical surface profilers. Source: Bruker Nano Surfaces Business

Microscopy

Technology Results in Sharper Images New microscopy technology breaks the optical diffraction limit while delivering lateral resolutions that were previously unattainable. BY K A RI O’ROU R K E, MAN AG I N G E D I TO R

R

eleased at the end of last year at the Materials Research Society (MRS) Fall 2010 Meeting in Boston, the AcuityXR from Bruker Nano Surfaces Business (Tucson, AZ), is an enhancedresolution microscopy technology available on select models of the ContourGTTM family of noncontact, three-dimensional (3-D) optical surface profilers. This innovative capability combines patent-pending hardware and software to determine what a part under test truly is while breaking the

optical diffraction limit. As a result, blurred features turn out sharper and the heights of narrow structures are more accurately measured. The technology is an extension of Bruker’s interferometric microscope capability and mostly enables these systems to exceed the capability of other optical profilers. It also extends the lateral resolution of optical profiling closer to the realm of atomic force microscopy (AFM) measurements, which in some applications will allow manufacturers to

measure their parts without resorting to slower and more complex technology. “AcuityXR increases the lateral resolution of select three-dimensional optical profilers by nearly a factor of three, allowing detection of features down to 130 nanometers in width on a wide variety of surfaces,” says Erik Novak, director, technology development optical products, Bruker Nano Surfaces Business. “This breakthrough technology therefore allows the fast measurement times, high vertical accuracy and repeatability of Bruker’s ContourGT optical profilers to be applied to measurement of narrower features, such as fine defects, small structures on MEMS devices, and structures in glass, semiconductors and polymers.” The company adds that the technology is not suitable for rough surfaces— those with surface roughness greater than 30 nanometers—but provides excellent capability for smooth surfaces, even those with large steps or other features. Surface defects often can affect function, performance, quality and manufacturing yields and are a concern to quality assurance and quality control (QA/QC) personnel. With this new technology, optical surface profiler systems can measure and resolve sample areas of interest under extreme magnification with zero or little stitched fieldsof-view, which improves ease of use. The higher pixel density from AcuityXR allows the resolution of nanometer-level features that have been impossible to resolve with conventional confocal or interferometric microscopy techniques. According to Novak, techniques based on microscopy in the visible

SPECIFICATIONS  Resolves features 130 nanometers in width  Minimizes optical effects, providing true dimensions of narrow features  Improves dimensional repeatability on nanoscale structures by a factor of 5X

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QUALITY | March 2011

 Allows wider field-of-view and higher pixel density than equivalent magnifications obtained with conventional means  Improves sharpness, clarity and definition of scratches, defects and surface texture

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 Shown here is an example of a grating sample with (left) and without (right) AcuityXR. Source: Bruker Nano Surfaces Business

range typically can only reliably image features down to about 500 nanometers in width, though most optical profilers claim capability down to the 300- to 400-nanometer range. In a study of line width metrology on 300-nanometer features, however, the AcuityXR improved the accuracy of the measurement by more than 25% and repeatability by more than a factor of five. Thus, reliable quantification is available on parts where before only a qualitative measure could be achieved. While the theory to increase lateral resolution of optical systems has been around for decades, and there has been great success with improved resolution in systems by the number of camera pixels available—such as in video or satellite images—Bruker was determined to extend the capability in a practical method to surface metrology, including when the resolution is curtailed by the optical diffraction limit. The technology has been in development for approximately two years, wherein a variety of approaches were tried and discarded before achieving a reliable method that worked on a wide range of samples under test. So far, the response has been positive. Novak says that the customers who saw the demonstrations claim that the images closely resembled those from Bruker’s AFMs. One customer in the energy storage industry decided to purchase their optical profiler with the AcuityXR immediately upon seeing the data and comparing it to scanning electron microscope images of the same surface. Uniformly, customers have been impressed with the lateral and vertical resolution provided by such measurements. For more information, contact: Bruker Nano Surfaces Business 2650 E. Elvira Rd. Tucson, AZ 85756 (520) 741-1044 [email protected] www.bruker-axs.com

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You asked. We answered. We completely redesigned our popular ACCURA CMM from the ground up to solve today’s metrology needs. The result is the perfect marriage of technologies ALL developed by Carl Zeiss. Visit us and experience productivity that only comes from a total system design … something you can’t see by looking at a specification sheet. German engineering. Built in America.

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50 Y e ar s of Qualit y of the manufacturQUALITY Laser Measurement Takes Hold ing process itself. The I information is critical for root cause determination and variation reduction. Most defective parts are not anomalies but rather the result of some change in the manufacturing process. When defective parts are detected, the most important question to answer is, “What is the origin of this error?” To more quickly determine the answer, manufacturers over the past decade have installed more measurement systems in their processes to aid root cause analysis. Instead of a single station to measure the body-in-white assembly, many automakers measure the completed underbody, body sides, framed body, doors and hoods. This step has helped manufacturers more quickly isolate problems at the subassembly level. But even that is no longer enough. Each subassembly is made up of numerous individual components that are assembled and welded together. The current trend is to strive for complete “diagnosability” of manufacturing processes to support very fast root cause determination. To do so requires the distribution of sensors throughout a manufacturing process rather than at a dedicated measurement station. For instance, some Audi assembly plants in Germany contain more than 25 laser measurement stations in their body assembly processes. Analytical models have been developed recently that determine what features to measure and where to measure them to obtain the most useful information with the smallest investment in equipment. MEASUREMENT, TEST & INSPECTION

U.S. automakers are expanding their use of laser-based dimensional measurement systems to help close the quality gap against foreign competitors. By R. Kent Gilbert

n the early 1980’s, North American automakers were feeling the effects of increased competition from their Japanese counterparts. Of particular concern to U.S. manufacturers was a perceived quality gap between U.S.-built cars and Japanese-made vehicles, which was driving more consumers to purchase imported cars. These trends spawned a renewed emphasis on quality in North American automotive production, at the same time that rapid advances were occurring in personal computers, lasers, cameras and image processing. When these areas came together to produce a new technology known as machine vision, U.S. automakers soon recognized its potential for use in improving vehicle quality. One of the earliest automotive applications for the technology was the use of laser-triangulation machine vision sensors and specialized algorithms to perform automatic dimensional measure-

ments aimed at quality control. Since then, the automotive industry has embraced the use of laser measurement, and its application has proliferated throughout the production process. The power of laser-based dimensional measurement lies in its combination of speed and noncontact measurement capability. Because a large number of measurements can be performed quickly and simultaneously without touching the car’s body, laser measurement systems can be placed “in process” to measure 100% of production. The original automotive application for laser measurement was dimensional verification of fully built, unpainted, “body-in-white” automobile body structural assemblies. Each completed body-inwhite passed through a measurement station to check if it was dimensionally correct. Rejected assemblies were repaired or scrapped, while acceptable assemblies continued through the process.

One of the latest uses for laser-based measurement systems is for checking the size of the gaps between body panels such as the hood and fenders or fenders and doors. Photo: Perceptron Inc.

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A Look Back at

Laser Measurement In this month’s edition of 50 Years of Quality, we take a look at how Quality has covered the relatively new technology of laser measurement over the years. HOW TO USE LASER MEASUREMENT CONFIDENTLY, JUNE 2001

QUALITY

Using laser measurement in dimensional applications results in fast, accurate and traceable results, provided that the measurement uncertainties are How to Use Laser Measurement Confidently correctly factored U into the equation. Lasers are inherently accurate because the wavelength of light, which is the basis of a laser system, has a high resolution that is linear and provides a stable reference for dimensional measurement. The most common laser-based measuring system couples the wavelength of light to the part to

METROLOGY

ometry, triangulation and scanning, the interferometry method is typically more accurate than other methods. Laser interferometers are used for the following reasons: 䡲 Resolution: The most common laser-based instruments resolve the wavelength of light to 0.1 micro-inch. 䡲 Stability: The thermal coefficient of expansion for the laser wavelength is more than ten times smaller than steel. Unlike steel, however, the laser beam is By Daniel J. Tycz minimally effected by changes in air pressure or humidity. The laser wavelength will change 1 part-per-million (or 1 microinch/inch), with an air temperature change of 2 F, an air pressure change of 0.1 inch of mercury or a relative humidity change of 30%. 䡲 Linearity: The wavelength of light is linear and does not suffer from linearity errors inherent in linear variable differential transformers (LVDTs) and glass scales. 䡲 Accuracy: Laser-based instruments ensure accuracy and traceability by two methods. A two-point mastering method determines the scale factor and datum by using two high-quality traceable gage blocks, a process that takes less than a minute to perform. A second method uses a traceable block to set the datum while the scale factor is determined by the wavelength of light, which is a physical constant. In this second method, the waveA 4-inch ring gage is placed on the measuring machine. The gage is being calibrated length of light is automausing a laser transducer. Photo: Siemens/Pratt and Whitney Metrology

By understanding uncertainty, operators can feel confident in their laser measurements.

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sing laser technology in dimensional measuring applications results in fast, accurate and traceable results, provided that measurement uncertainties are correctly factored into the equation. Lasers are inherently accurate because the wavelength of light, which is the basis of a laser system, has a high resolution that is linear and provides a stable reference for dimensional measurement. The most common laser-based measuring system couples the wavelength of light to the part to be measured by using a fringe counting laser interferometer to detect linear motion of a probe that contacts the part. Although various methods are used for laser measurement, including interfer-

QUALITY / June 2001 http://qualitymag.com

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QUALITY | March 2011

be measured by using a fringe counting laser interferometer to detect linear motion of a probe that contacts the part. Although various methods are used for laser measurement, including interferometry, triangulation and scanning, the interferometry method is typically more accurate than the other methods.

LASER MEASUREMENT TAKES HOLD, AUGUST 2002 The original application of laser measurement in automotive manufacturing was a single station at the end of a bodyin-white assembly line that checked each part and prevented any defective parts from continuing in the process. However, because the in-process station measures every assembly being produced, it also becomes a barometer

QUALITY / August 2002 www.qualitymag.com

LASERS, A PRACTICAL TOOL FOR INSPECTION, NOVEMBER 2005 It’s no wonder that laser measurement has been moving into manufacturing in a big way lately. Laser scanners are fast and accurate measurement devices that lend themselves to automation. They can collect a cloud of datum points automatically on contours and features in a matter of minutes and then send the points to software for comparison against known values. Consequently,

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they are making it practical to make many more measurements and conduct more thorough inspections than before—and often do them in less time. Because they fulfill the needs created by the demand for full-surface inspection, faster data collection and greater automation, laser scanners are now busy at work inspecting a variety of parts across many industries. They are checking parts small enough to fit in one’s hand, measuring engine castings in automobile factories, and providing important feedback for the Boeing 787 and Joint Strike Fighter programs. Despite these recent successes, laser , scanning has been A PRACTICAL TOOL FOR INSPECTION slow to catch on in I factories. Sure, lasers have found inspection applications there all along, but their most common industrial use has been in design studios,

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LASERS S C A N N E R S C H E C K P R O D U C T I O N PA R T S . B Y JA M E S R . KO E L S C H , C O N T R I B U T I N G E D I TO R

t’s no wonder that laser measurement has been moving into manufacturing in a big way lately. Laser scanners are fast and accurate measurement devices that lend themselves to automation. They can collect a cloud of datum points automatically on contours and features in a matter of minutes and then send the points to software for comparison

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QUALITY | November 2005

against known values. Consequently, they are making it practical to make many more measurements and conduct more thorough inspections than before—and often do them in less time. Because they fulfill the needs created by the demand for full-surface inspection, faster data collection and greater automation, laser scanners are now busy

at work inspecting a variety of parts across many industries. They are checking parts small enough to fit in one’s hand, measuring engine castings in automobile factories, and providing important feedback for the Boeing 787 and Joint Strike Fighter programs. Despite these recent successes, laser scanning has been slow to catch on in

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where they caught on as reverse engineering and modeling tools from their earliest days in the 1980s. The situation has changed, however, over the past five years or so. In fact, Jim Clark at Metris USA Inc. (Rochester Hills, MI) reports that most of the laser scanners that Metris sells now are for inspection.

laser triangulation is currently about as fast and as accurate as it can get. “More Lasers economical systems Pinpoint Measurement will be introduced that will have more features for the dollar,” he says. “Laser sensors with less than 0.03% linearity are at their limits of what is physically possible in spot penetration. So there will be even more sophisticated systems with even higher integration of intelligence to improve the performance.” Until now the majority of laser scanners have been manually operated and flexible. Giles Gaskell, director of business development at NVIsion Inc. (Wixom, MI), says this is ideal for design and development environments, but less so for in-line applications. He forecasts increasing numbers of in-line contact measurement solutions available in the future. |

Q UA L I T Y M E A S U R E M E N T

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ow does laser measurement pinpoint quality? The answer to this question is a broad one, even for such a precise and exacting measuring technique. Laser measurement uses the optical properties of focused light for noncontact dimensional scanning of a subject part, material or object yielding 1D, 2-D or 3-D coordinate point surface positional information. Its use in manufacturing-related activities consists of collecting many times more measured points in a given time compared with conventional techniques, allowing better definition of complex geometries. Engineers and designers confirm quality by using the data from laser measurement devices to reverseengineer, improve or create new parts and products, or improve how parts are

H

Lasers are ensuring quality with accuracy at high speeds, more information in less time and contactless measurement. B Y M A R K RO B I N S, S E N I O R E D I TO R made. Quality control personnel use laser measurement to verify that parts have been made correctly, and if not, where they need to be corrected. Laser measurement ensures quality in manufacturing-related activities by creating absolute references for measurements, which do not change over distances the way mechanical or relative references do. Fast data acquisition is possible without the potential distortion that often occurs with conventional contact measurement. Because a laser does not touch the part it is measuring,

the laser is not compromised when measuring soft materials, which might move or wear when touched. Compared to conventional contact measurement, laser measurement has fewer moving parts required to manipulate the part or the contact device. “This will increase the durability and longevity of any manufacturing cell,” says Stephen Sochowski, director of sales and marketing at Micro-Epsilon (Rolling Meadows, IL). “Many contact devices can and will break, and must be replaced which increases downtime. Because tolerances

TECH TIPS

 Laser measurement ensures quality in manufacturing-related activities by creating absolute references for measurements.

LASERS PINPOINT MEASUREMENT, NOVEMBER 2006

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In the future, as computers get faster, laser measurement will further ensure quality by producing more data per second from scanners. Increased competition should force prices to decrease. There will be a wider range of localizing devices, improved software and higher speeds of data acquisition. Devices should become lighter and smaller, have higher accuracies and distance capabilities, and enhanced automated feature recognition. According to Martin Dumberger, vice president of Micro-Epsilon (Raleigh, NC), semiconductor-based

 To ensure quality, laser measure-

ment suppliers are simplifying procedures, and providing improved design, automation and fixturing.

 Laser systems range from single-

axis measurers to large 3-D point cloud devices.

QUALITY | November 2006

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Don’t Leave Out

Fixturing W

hen purchasing a coordinate measuring meas ring machine (CMM) or vision machine, a commonly overlooked item is the fixturing. Fixturing is an important consideration as it is needed for holding various types of parts that need to be inspected. Fixturing should be included at the time of the CMM or vision machine purchase so the machine can inspect parts as soon as it is set up. You would not buy a machining center without the right fixturing equipment for the application;

The right fixturing is the key to getting complete success and production from inspection equipment. BY DEBBIE RAY

the same holds true for a CMM or vision machine. Fixturing should be the second priority, after the equipment itself. Without the purchase of fixturing at the time of the CMM or vision machine installation, too many CMMs or vision machines sit idle and unproductive

because they are not efficient, particularly because there is no way to hold parts securely and repeatably. Most CMMs do allow for threaded holes on the measuring surface to help hold and position parts on the machines. Unfortunately, the spacing of these holes can vary so much that

TECH TIPS  Fixtures can hold any variety of part materials, shapes and sizes.  Custom fixtures are designed and built for a specific application such as a high-volume production part with a complex geometry.

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QUALITY | March 2011

 Modular fixtures are a cost-effective method of fixturing most parts using the same fixture and components with the capability of presenting a part in the best attitude for the inspection equipment.

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 Custom fixtures are designed and built for a specific application such as a high-volume production part with complex geometry. Source: R&R Sales and Engineering

they may not be useful, depending on the part size that needs to be held. Vision machines have only a glass stage with even fewer holes, if any, around the stage perimeter itself. With these limited number of holes on the machines, it makes it difficult to secure the part and re-locate the part in the same position each and every time. These machines generally do not come with any fixturing components that would enable the use of the threaded holes, unless purchased separately, so at that point the threaded holes are useless. This is where fixturing begins to play an important role.

to elevate, locate and secure a part into position. Adjustable components are available that level or locate a part at the desired position to best access it for the necessary measurements. In modular fixturing setups, various clamps and magnets can be used for securing a part. Modular fixtures can

fixture parts and provide flexibility for quick changeover to another part in just a matter of minutes. There is no downtime waiting for a fixture to be designed and built. Modular fixtures can be used every step of the way from prototype work to production, a feat not so easily accomplished with custom fixturing.

APPLICATION-DEPENDENT There are two types of fixturing for CMMs and vision machines: custom and modular. The best option depends on the application. Modular fixtures are a costeffective method of fixturing most parts using the same fixture and components with the capability of presenting a part in the best attitude for the inspection equipment. Custom fixtures are designed and built for specific applications, such as a high-volume production part with complex geometry. Fixtures can hold any variety of part materials, shapes and sizes. Most commonly used modular fixtures start with a base plate that can accommodate many different part sizes depending on the application or the size of the CMM or vision machine used, whereas a custom fixture is more specific to the size of the part to be fixtured. A modular base plate with threaded holes in a geometric pattern can allow more flexibility to hold any size, shape or type of part to be inspected, as opposed to to the limited number of holes on a CMM or vision machine. Some modular fixturing companies offer various thread sizes, hole spacing and components to hold the smallest most intricate part inspected on a vision machine up to the largest, heaviest parts that can be checked on a CMM. There is no limit with modular fixturing as there are many different options of fixturing components used

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March 2011 | QUALITY

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Modular fixturing is normally less expensive than custom fixturing and has the flexibility to hold almost anything within a matter of minutes. Source: R&R Sales & Engineering

GETTING HELP Some modular fixturing companies offer alphanumeric-labeled plates and components to document and record the fixture setup. One fixturing company provides software to model a part and fixture in 3-D modeling. This enables the operator to perform offline inspections and document the process as inconsistent fixturing methods can produce inconsistent results, meaning it is important to set a standard way of fixturing parts each and every time they are inspected. This makes the CMM and vision machine more accurate and consistent. Make sure when choosing a modular fixturing company that each of

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QUALITY | March 2011

these fixturing components can be identified—for example, using part numbers. Correct, legible, long-lasting component identification improves fixture repeatability particularly when more than one operator is involved in the part setup or it has been some time since the part setup was previously done. Looking into fixturing earlier in the process and deciding what type of fixturing will best fit the parts also gives the opportunity to allow for lead times. The more time and effort invested in the beginning, the better the return in the long run, since many custom fixtures can take months to design and build. Some modular fix-

turing companies do stock fixturing plates and components, but planning ahead for extra lead time if a specific plate size and mounting holes are needed to fit the machine will ensure that a company will not delay the introduction and start up of its inspection equipment. Another important consideration when exploring which fixturing avenue to take is to look into the sources and capabilities each fixturing company offers. Is a combination of custom and modular fixturing needed? The more components and design options that a fixturing company offers, the more flexibility there will be to set up all of the parts using either modular or custom fixturing. If the fixturing provider is limited in its component selection or engineering capabilities, a company may run into difficulty holding complex parts. The cost of fixturing also can be an issue. It should be addressed up front as many times the entire budget is spent on the machine and there is nothing left for fixturing. Why buy a machine if there is no fixturing budget to go with it? Modular fixturing is normally less expensive than custom fixturing and has the flexibility to hold almost anything within a matter of minutes. It also can be documented, set up again, and used repeatedly as opposed to custom fixturing, which is specific to that part or application. Custom fixturing can be more costly with engineering concepts, design and build of a fixture. It is necessary when a part has complex geometry, intricacy or orientation requirements that it be held in a way that allows for probe clearances and secure access in a particular way. Using a fixturing company that has a sales and engineering staff familiar with the use of touch probes and backlighting is critical to fixturing success. In the case of modular fixturing, the provider can assist in ordering the correct fixturing base plate and components. When working with custom fixturing provider, they will be able to design and build a fixture the right way the first time. They know up front the limitations and interferences of CMM and vision machines capabilities.

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Whether purchasing a CMM or vision machine, keep in mind the success and payback from the inspection equipment comes faster if fixturing is a priority that is not missed or overlooked. The right fixturing—modular or custom—is the key to getting complete success and production from the inspection equipment. Fixturing can help a company make quality products as the part will be held securely and consistently the same way on the fixture each and every time, gaining valuable inspection results and success with inspection equipment. Q Debbie Ray is sales manager for R&R Sales and Engineering (Grand Haven, MI). For more information, call (616) 847-6045, e-mail rrsales@ cmmfixture.com or visit www.cmmfixture.com.

QUALITY ONLINE For more information on fixturing, visit www.qualitymag.com to read the following: • “Fixtures Meet Need for Flexibility” • “Fixturing Presents Quality Products” • “Simplicity Key to CMM Fixturing”

There is no limit with modular fixturing as there are many different options of fixturing components used to elevate, locate and secure a part into position. Source: R&R Sales and Engineering

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Hardness Testing Market T

he use he u se of of hardness h a rd ha rdne d ne ness ss testers t es este ters te rs as as a relatively rel re l ati la tive i ve velly l y ssimple i mpl im ple and and economiecon ec onom on omiiom cal testingg mechanical ca method et od of o test ec a ca properties dates back more than 100 years. During that period trains, planes and cars have become faster, safer and more reliable. Material science, biomedical and nanotechnology has progressed at a tremendous pace. In addition, the world continues to strive to develop cleaner energy technologies. Through all these advances that continue to improve day-to-day safety and quality of life, material testing equipment has played a critical and

Makes Adjustments

The shift toward the automation of hardness testing is a strengthening trend. B Y V I JAY MATH E W often understated role. For those not involved in the realm of manufacturing or product development, the contribution of hardness testers is mostly overlooked. However, 2010 was a stark reminder of the importance of such quality control measures in the wake of

expensive and widely publicized industrial disasters and product recalls.

OPENING DOORS TO NEW OPPORTUNITIES As the saying goes, when one door closes, another one opens. This is

TECH TIPS  A key force behind the drive toward automation of hardness testing equipment is the need to ensure accurate and high-quality results.

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QUALITY | March 2011

 Rather than buying a brand new hardness tester, customers are turning to their equipment suppliers for service, repair or refurbishing of their existing equipment.

 The challenge for hardness test equipment vendors lies in creating a cost-effective platform to meet the specialized needs of a wide range of customers.

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 Technology advances have helped make hardness testing equipment easy-to-use, faster and more reliable. Source: The Zwick Roell Group

particularly true for the hardness test equipment market, with some of its biggest users—such as the automotive and steel industry—going through one of the most difficult periods in recent history. Although the market has gradually recovered, in North America and Europe cost control and budget issues still remain a key concern; evidence that the lingering effects of the 20082009 downturn still poses a challenge for hardness test equipment vendors. However, many of those concerns have been alleviated by opportunities arising from different parts of the globe. Countries such as India and China have been almost recessionproof and are driving a considerable level of innovation and growth of hardness testers. China and India are the two fastest growing economies in the world and in line with this economic growth, energy, infrastructure, manufacturing, construction and transportation demands also have greatly increased, creating a massive requirement for hardness testing equipment in these countries. Russia is another market with huge potential. Although Russia is considered a difficult market in which to do business as conflicts with American standards still exist, the country has undergone several economic reforms and is expected to demonstrate strong and resurgent growth over the next five to eight years.

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“What we’ve seen specifically since the downturn started is growth for orders in India, China and Russia,” says John Piller of Indentec, Zwick Roell’s hardness testing division. “So, we haven’t really seen any downturn. In fact, in the last two to three years we’ve seen nice growth in all of those three emerging economies, primarily supplying European and American companies who have invested in setting up manufacturing facilities in those regions.” The leading companies in the hardness testing business, such as the Mitutoyo America Corp. (Aurora, IL), The Wilson Hardness Group (Norwood, MA) and The Zwick Roell Group (Ulm, Germany) among others, have been quick to respond to evolving conditions to capitalize on market opportunities. With a strong financial backing and network of sales, support and distribution operations across the globe, these companies have been successful, to a certain extent, at weathering the storm. On the other hand, companies with core customer bases restricted to certain geographies, primarily North America and Europe, have found it difficult to cope and will be looking forward to 2011 and the new opportunities ahead. Another segment of the hardness testing business that has witnessed a spike in interest following the econom-

ic downturn has been the services market. The unfavorable economic climate has caused end users to rethink their capital expenditure strategies. So rather than buying a brand new hardness tester that can set the operator back anywhere between $2,000 to $50,000 for a fully automated instrument, customers are turning to their equipment suppliers for service, repair or refurbishing of their existing equipment. According to Bill O’Neill, director of business development and sales for The Wilson Hardness Group, a division of Instron, success in this industry is defined by working closely with customers. “A lot of our market is automotive or automotive supply-based,” he says. “Therefore, everyone from the big automotive suppliers to the people that feed them took a big hit in 2009. However, that translated to end users doing more services on their machines. Also helping people do more with less people. Customers had to trim their employee base but often had to continue the same level of testing. One of the challenges we met was to help people work efficiently with less.”

AUTOMATION—THE DECISIVE FACTOR A common misconception among testing circles is that hardness testing equipment has not embraced technology to the same extent as some of its other test and measurement counterparts. Although the fundamental mea-

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it was about 10 to 15 years ago. surement technique remains relaCustomers are now happy to have tively the same, leading hardness their measurement parameters test equipment manufacturers met by a mere push of a button are now offering their customers rather than relying on the data the most sophisticated qualinterpretation capabilities of an ity control solutions out there, inexperienced operator. integrating the latest advances in However, according to Piller computing, software, X-Y table this has had little bearing on the and stepper motor technology. automation trend, highlighting These technology advances have that it is quality driven rather helped make hardness testing than being about lack of skilled equipment easy-to-use, faster and operators. “Yes, there are some more reliable. skill shortages. However, it’s not “Currently, close to 50% of rocket science. And with some what we supply has a computer good training from the supplier attached to it and that number of the hardness tester, you can get is growing,” Piller says. “The just about anybody to get good other 50% is still a manual quality results.” environment but those customers are really not carrying out The market is witnessing a trend toward automatic too many tests.” SMALL IS THE NEW BIG hardness testers in order to reduce operator influence This opinion is echoed by othEverything seems to be getting and uncertainty of measurement. Source: Zwick Roell ers in the industry. “Demographsmaller these days, and subjectics are changing and we are moving miniaturized components NADCAP have been set up to ensure ing toward a demographic that insists to material tests poses some of the compliance with the latest hardness on having automated data collection, biggest technical challenges for hardtesting standards for aerospace manumanipulation, storage and computerness test equipment vendors but at the facturers and their supply chains. ization,” O’Neill says. same time is one of the fastest growing Conformity to the highest levels of A key force behind this drive toward application markets. “Micro Vickers quality particularly in safety critical automation of hardness testing equipis where we see the biggest increase in applications is of primary importance ment is the need to ensure accurate potential orders for the next five years,” to customers and, as a result, the and high quality results. Bodies such says Piller. “That’s the area that we put market is witnessing a trend toward as ASTM and ISO continue to modin most of our research and developautomatic hardness testers in order to ernize and evolve standards and speciment (R&D) capability because that’s reduce operator influence and uncerfications in accordance to changing definitely a fast growing market and tainty of measurement. market conditions. customers want to test smaller parts; Another important factor to conMoreover, with the continuing trend thinner coatings; and thinner, smaller sider is that the skill sets of current toward outsourcing of manufacturing and cheaper processes, and they expect operators is nowhere close to what operations, auditing bodies such as the same level of accuracy of results.”

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The continued drive toward smaller, faster and cheaper materials in industries such as semiconductor, biomaterials and fibers has created the need for more accurate and standardized test equipment. The challenge for hardness test equipment vendors lies in creating a cost-effective platform to meet the specialized needs of a wide range of customers. As a result, in many cases, test equipment vendors are unable to meet necessary requirements and customers depend on in-house developed testing solutions. This segment of the market, however, is in a state of continuous improvement with ever-evolving technologies broadening the scope of hardness testing equipment beyond its traditional markets.

times. As global markets climb out of the recession, 2011 promises interesting times. From a technology perspective, automation will drive the market for the next few years with a significant percentage of product introductions expected to follow this trend. There are still certain applications where traditional instruments will continue to play a role, but as technology and the market needs evolve, the shift toward automation of hardness testing is a strengthening and undeniable trend. Q Vijay Mathew is an industry analyst for Frost & Sullivan’s Measurement & Instrumentation (Mountain View, CA). For more information, call 91 44 39144890 or e-mail [email protected].

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The past two to three years has been a period of adjustment in the hardness test equipment market. Vendors were required to re-align and reorganize their strategies to help customers do more with less in tough economic

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Calibrations in the Cloud C

loud computing has been an IT buzz word for several years. It is now mainstream. Calibration management software is no exception in the trend to move business application software to the cloud. Many people have probably heard of cloud computing. In fact, most people use cloud computing whether they realize it or not. If you are using Inter-

For organizations looking to upgrade or replace their current calibration system, cloud computing is an option worth investigating. B Y DAV E B AN E R J E A net search engines; Web-based e-mail such as Yahoo, Hotmail and Gmail; social networking systems such as Facebook and Twitter; or even online

banking, then you are already using cloud computing. Let’s take a closer look at cloud computing, how it applies to calibra-

 Though market demand was initially low, there has been a slow, steady increase in demand over the years for calibration software that runs through a Web browser.

 Providers of cloud services have multiple lines of redundancy, multiple layers of defense and multiple levels of security that a single company usually could not afford on its own.

TECH TIPS  Cloud computing is a newer delivery model for IT services and software that usually involves scalable and virtualized resources as a service over the Internet.

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tion management software and why it is relevant, as well as examine some of the major benefits and risks of this emerging technology.

WHAT IS CLOUD COMPUTING? The term cloud is just a metaphor for the Internet, which is typically drawn as a cloud shape on network diagrams. Cloud computing providers deliver various business software applications, which are most often accessed from a Web browser. The main distinction of cloud computing vs. traditional computing is that the software, data and computer processing reside on a service provider’s servers. This is really just Internet-based use of computer technology. The technical details are masked from the users who no longer need to have expertise in the technology that supports them. In traditional software applications, the user needs to care about what operating system the application will require and hardware requirements such as hard drive space, CPU speed and RAM. He also needs to care about the database system it requires to store his records, such as SQL Server, Oracle and DB2. Cloud computing is a newer delivery model for IT services and software that usually involves scalable and virtualized resources as a service over the Internet. Much like the electric service, it can be scaled to accommodate whatever the user needs, and the provider uses whatever resources—such as coal, solar, nuclear or wind—to generate the electricity. The consumer does not need to know the technical details—he

Oil & Gas

Technologies such as Microsoft’s Silverlight allow developers to create richer user interfaces that improve usability with cloud computing applications. Source: CyberMetrics

just wants his lights to go when he flicks the switch.

MOVING CALIBRATIONS TO THE CLOUD While there are only a handful of companies currently offering calibration management software systems that can be run through a Web-browser, there are still fewer that provide this software as a service (SaaS) through cloud computing. One of the reasons for the lack of choice is the lack of need.

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In a typical medium-sized manufacturing facility there are perhaps only one or two technicians who use calibration management software. In a larger facility there may be five to 20 users. It is not too difficult or costly to set up and maintain traditional desktop software for so few users. Compared to enterprise resource planning (ERP) and customer relationship management (CRM) soft-

Software

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ware, which may have a hundred or more users in a medium-sized facility, the value proposition for cloud computing is significant since there are so many users. The effort and costs to deploy, manage and maintain desktop-based software for so many users are huge. As a result, there are many competitive choices now available for ERP and CRM cloud computing. It is no won-

der that an enterprise cloud computing company such as Salesforce.com generates close to $1.5 billion annually on its CRM system. Software giants such as IBM, Oracle and Microsoft have taken notice and all have offerings for cloud computing. They know where this is trending. In the field of quality assurance and control, there are some cloud and Web-based management systems

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for statistical process control (SPC), document control, failure mode and effects analysis (FMEA), and corrective actions. But again, the choices are few at present. This will change in the coming months and years as the market learns about the benefits of cloud computing and demands that traditional desktop software be moved to the cloud. As for calibration management software, a few vendors were early to market with Web-based software and have been offering solutions for more than a decade. Though market demand was initially low, there has been a slow, steady increase in demand over the years for calibration software that runs through a Web browser. One popular package initially included Web modules that would front-end the desktop software mostly for reporting. Later on, other modules were developed for entering calibration data through a Web browser and for creating aggregated reports across multiple facilities. Yet, in most cases, customers host their software and databases locally on their internal networks and run the Web-based modules over their own intranets. In the past couple of years, some larger clients, particularly those with many facilities and users, have completely shifted their calibration system to the cloud by having the provider host both their software and data. For better security, they typically access their software through the Internet using a secure connection that encrypts all incoming and outgoing data with secure sockets layer (SSL). Their IT departments are quite happy since there are no servers to buy and set up, no deployment efforts—other than sending an e-mail to the users with the link and logon credentials—and no maintenance is required because the provider takes care of their database backups and software updates. Software users also are happy since they can access their software from any computer that is convenient, receive automatic updates without IT involvement and can lookup information while on the road. Cloud computing also supports easy set up of remote-access accounts for

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calibration service providers to enter measurement data and calibration certificates for their clients.

For organizations looking to upgrade or replace their current calibration system, cloud computing is an option worth investigating for its potential benefits.

PROS AND CONS There are many good reasons to go with a cloud computing software application. Some reasons to consider using them include: • Cost Efficient. The service provider will host services for multiple companies. Sharing complex infrastructure is cost-efficient and the user only pays for the services he actually uses. • Fast Deployment. The most basic cloud services work out of the box and can be ready to use in just a few hours or a few days. For more complex software and database solutions, cloud computing allows for skipping the hardware procurement and capital expenditure phase—it is perfect for new facility start-ups, those with limited IT budgets and organizations without in-house IT expertise. If roll-out to multiple facilities is needed, going

with cloud solutions is a compelling option. • No Maintenance. Most providers constantly update their software offerings, adding new features and software patches as soon as they become available. • Highly Scalable. If a business is growing or has seasonal spikes, it can scale up quickly because cloud systems are built to cope with sharp increases in workload and in the number of users. On the other hand, it is just as easy to scale down when services are no longer needed. • Mobile. Cloud services are designed to be used from a distance, so if a company has a mobile workforce,

its staff will have on-the-go access to its systems. Cloud computing also has raised some concerns. Providers are well aware of these and continue to find ways to eliminate risks and reduce these concerns. Some of the top concerns include: • Customizing Expenses. While traditional applications have many features to cope with specialized needs, customizing a cloud service typically costs more. However, most providers are able to roll-out newly developed features to all customers much more quickly than traditional application software vendors.

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Shown is an example of a Web-based calibration management module that is part of a larger enterprise asset management system. Source: CyberMetrics

NE

• Usability. Usability is an issue. Some people are firmly tied to their existing traditional software. They are reluctant to switch to plainer online applications that may not have all of the user interface features and functions to which they are accustomed. Although providers are somewhat hampered by limitations of the browser, efforts are constantly being made to bring parity between traditional and cloud application software. One example is shifting some of the user-interface processing to the user’s local computer (client side) so the application is more responsive. The use of Asynchronous JavaScript and XML (AJAX), Adobe Flex and Microsoft Silverlight are examples of technologies that improve usability and provide a richer desktop-like experience to users of Web-based and cloud applications. • Connectivity. Connectivity is another worry. Users of cloud systems must have the proper Internet bandwidth and connection reli-

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ability in order to fully utilize the system. That is not to say that all problems are on the user side. Sometimes cloud services do fail and go down, but this is rare due to redundancy and failover systems. However, most problems are rooted more in the client organization’s internal network. • Security. Security concerns are a big issue. Customers need to know that their data will be safe and protected. In some cases, there are legal compliance requirements—such as those for finance, human resources and healthcare applications—and also regulatory issues such as for medical, pharmaceutical and defense industry manufacturers. For business security, there is the concentration of corporate risk in one single place. If a company is running its CRM in the cloud, it certainly does not want competitors gaining access to its customer database. Likewise, it does not want competitors gaining access to proprietary formulas, process setups and

Cloud computing is a newer delivery model for IT services and software that usually involves scalable and virtualized resources as a service over the Internet. capacity information stored in an ERP system. Providers of cloud services have multiple lines of redundancy, multiple layers of defense and multiple levels of security that a single company usually could not afford on its own. While larger business software applications such as CRM and ERP already have moved to the cloud for reasons of cost efficiency, reduced maintenance costs, centralized management and easier deployment, smaller and more specialized software applications such as calibration management also are making the move for many of the same reasons.

For organizations looking to upgrade or replace their current calibration system, cloud computing is an option worth investigating for its potential benefits. Q Dave Banerjea is founder and CEO of CyberMetrics Corp. (Phoenix). For more information, call (800) 777-7020, e-mail dave@ cybermetrics.com or visit www.cybermetrics.com.

QUALITY ONLINE For more information of calibration software, visit www.qualitymag.com to read the following: • “Calibration Made Simple” • “Successful Software Selection”

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Taking Quality to the

Customer G

ive customers exactly what they need most. That can be a tall order for some companies, but for the Daimler Trucks North America (DTNA) Cleveland Truck Manufacturing Plant (CTMP) in Cleveland, NC, it is all in a day’s work. Plant Manager Mike McCurry jokes that his plant is the Burger King of trucks—you get it your way. CTMP builds five different class 8 truck Freightliner models—Argosy, Columbia, ST, Cascadia and M915A5 military. Each of these models can be ordered with different configurations based on the customer’s application.

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Unlimited options include cab type (day cab or sleeper), cab height, drive train configuration, and even the paint color—there are more than 10,000 colors to choose from, including about 200 different shades of white—and scheme. In addition, CTMP supplies trucks to the NAFTA, Australian, New Zealand, Chile, South African and

U.S. military markets. Each of these markets requires that the truck meet different exhaust emission standards. These standards dictate the engine model and exhaust configuration. Adding one more piece of complexity, the Australian, New Zealand and South African trucks are built as righthand drives.

CTMP AT A GLANCE  Location: Cleveland, NC

 Opened: 1989

 Size: 1 million square feet

 Employees: Approximately 1,180

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QUALITY | March 2011

 Product: Five Class 8 Freightliner models—Argosy, Columbia, ST, Cascadia and M915A5 military

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Source: DTNA CTMP

Source: DTNA CTMP

Source: DTNA CTMP

all of the specs are correct and everything is the way they want it.” In one instance, the customer was not able to make it to the plant, so CTMP took the truck to the customer—six hours away. “Without that customer interaction, we can build a truck to the expectations that we think it should be, but without that you never know if you’re truly building it to what the customer wants unless they come and tell you, ‘OK, this is what we see,’” says Smith. “And it’s really what we calibrate off of and then step up to the next level and raise the bar.” McCurry says that customer perception and the quality of the trucks is better than ever.

BEST IN CLASS Realistically, each of the approximately 60 trucks being assembled on a given day could be a different specification. “It’s amazing the different set of expectations customers have,” says Brian Smith, cab assembly manager. These differences are generated around the variations of applications and customization of the product. In order to give the customer what he wants, CTMP gains an understanding of what the customer wants well before the truck is built. Quality Manager Chris Harris explains, “Normally, when we prepare to build a fleet for a customer, we’ll conduct a pilot review with the customer by building one of their trucks about six weeks prior to the fleet starting. The customer will come in and review the build quality and truck specification. The purpose of the pilot is to make sure

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McCurry says that the Cascadia is the best Class 8 truck in the market and the growing marketshare proves it. To make the best truck possible, DTNA made a conscious effort to design the new Cascadia the right way from the beginning. They talked to customers and went to trucks stops and asked drivers, “What do you want to see?” The production workers also worked with the design engineers from the beginning to get the process right. Of the approximately $80 million invested in the Cascadia line, nearly half of the investment was in automation, says Rod Rayl, cab in white manager. Automation provides several advantages when it comes to quality. Robot processes are repeatable and can be designed to detect problems. For example, the cab assembly robotic cells are designed to prevent operator error by having a built-in Poka-Yoke. The

assembly process will not start until the system has verified that all parts are placed correctly in the fixture, a check accomplished with proximity sensors. Also, the cab assembly process contains an automated vision inspection cell, ensuring that the cab is dimensionally correct and that it is built per the cab specification. In addition to the robotic assembly processes, CTMP uses DC or pneumatic torque-controlled tools throughout the assembly process. By using torquecontrolled tools, the likelihood of having loose components is greatly diminished over the life of the truck. Also, by installing fasteners to correct torque, the potential for damaged components from overtightening is prevented, reducing scrap at the plant. But not all of the work is automated. Human interaction check points have been inserted throughout the process to make sure things are put together correctly, because if it was all automated and something broke in the beginning, you would never know it, explains Rayl. Harris adds that defined quality gates have been installed throughout the plant where some are staffed by quality control and others are staffed by the responsible production department. Cab in white, Rayl’s area, is one of the areas where they do their own inspections. “By using standard work and the defined quality processes, the operators know what they need to do, and what should be coming to them from the previous station,” continues Rayl.

TOS IN DETAIL “When I first became a quality manager, I thought the whole process should

March 2011 | QUALITY

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be about building quality,” Harris says, “but after meeting with the customers, you realize it’s more than that. They want the trucks on time and they want us to reduce cost. Quality is more than how you build a truck; it’s the whole process of how you build a truck.” With nearly a trailer-and-a-half of parts to build one truck and endless customer customization possibilities, how is quality maintained throughout the process with so many possible variations? The process has been made easier by implementing a truck operating system (TOS). The TOS is the CTMP’s foundation to develop and live within lean processes and continually improve. TOS contains “the know what” and “the know how” to continually improve within a lean culture. CTMP has succeeded in improving quality by creating a lean management system to drive the production system. In other words, the lean management system uses the appropriate tool within the production system to achieve the desired result. CTMP uses a variety of TOS tools to continually improve quality: qual-

ity feedback loops, standard work instructions, production process assurance, quality alert andon systems and problem-solving processes. Each of these tools has an individual purpose that can improve quality, but when they are used in conjunction, the result is world-class quality. • Quality feedback loops. The quality feedback loops start at the team member level and extends to the end customer. Each of the quality feedback loops is intertwined so that information flows from the customer to the team member. Also, processes have been created within each loop to improve quality and address issues quickly. • Worker self control. The goal of worker self control is to build quality into a station and prevent a defect from reaching the next station. At the team member level, standard work instructions (SWI) define the process steps and quality checks to complete each assembly job safely. Smith says, “Because of the complexity and the customization in

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Source: DTNA

these trucks, you have to give [team members] a standard and a process to follow. “Someone may be on vacation or a job transfer may have occurred, so you have to have a starting point [standard work] for our team members,” Smith continues. Standard work provides the detailed instructions for performing the processes so that the level of quality is not compromised in these situations. Harris comments that not only are the standard work instructions to work by, but they are also to improve by. Smith continues, “As the process changes, we’ll either update it or completely change it. It’s a living, working document all of the time.” If the team member encounters a problem or question while performing his job, he activates his andon—a battery hooked to an alarm—to notify his team leader. Because some work areas are larger than others, the alarm serves as a way to attract the team leader’s attention, no matter where he may be in the work area. The true

intent of the andon system is to let the team member announce they have an issue before the problem actually impacts them. When an issue arises, the first question asked is “What is the standard?” If a problem exists, it comes down to three things—the process does not have a standard; the standard is incorrect; or the standard was not followed. If for some reason the issue could not be corrected, the team member records the discrepancy on his production process assurance form (PPAF) so that the issue is repaired downstream. The PPAF is used throughout the production process and is a permanent record kept with the truck file. • Quality gates. Quality gates manned by inspectors have been established throughout the production process to control first-time quality and to ensure that no defects leave the production area. The inspector veri-

fies the customer’s sales order to the truck specification while inspecting workmanship. The inspector also has a defined standard for inspection within the quality gate. The inspection standard is defined by an inspection checklist, which includes standard items and dynamic items that are checked on each unit. The dynamic items are added to the checklist based on internal and external customer feedback. When an inspector finds a discrepancy, the defect is noted into a database of the truck history. Reports can be generated from the database to highlight repetitive

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March 2011 | QUALITY 10/7/08 10:14:23 AM

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Q UA L I T Y M A N AG E M E N T

| and proper tooling is used. an They also verify that toolT ing is functioning correctly. in The product auditors have T extensive knowledge of the ex eengineering standards, but they also have been trained th tto see the truck through tthe customer’s eyes. The product auditors have p aacquired this perspective by reviewing feedback from b ccustomers and by conductiing consistency reviews with customers and field service. By having the balance of knowledge between engineering build standards and the customer’s expectations, the product auditors ensure that the truck is built with worldclass quality. To distribute this knowledge into the manufacturing processes, one truck per shift is pulled from the end of the main assembly line (EOL audit) for a customer perception audit. Any issues noted during the audit are fed back to the team

Source: DTNA CTMP

problems. The problems then can be added to the inspection checklist or the SWI as a quality check. • In-line production audit. An in-line production audit is staffed by quality department auditors who audit the product and the production processes. Their purpose is to ensure that the product released from the production areas meets engineering standards and customer expectations. The process auditors verify that the assemblers are following manufacturing work instructions

Extensometers

Strain measurement for materials testing

responsible. These issues also are added to the inspector checklist for the quality gates. The EOL audit focuses on first-time quality and demonstrates how the quality feedback loops are intertwined to flow information from the customer to the team member. • Assembled product audit. The assembled product audit focuses on the customer. This feedback loop encompasses all external feedback such as warranty, dealer feedback and direct customer communication. The assembled product audit, or APA, mimics the EOL; however, APA focuses on trucks ready for delivery to the customer where EOL focuses on trucks within the production process. In addition, the APA includes the dynamic vehicle test (DVT). Each day a DVT is performed on one of the APA trucks. The DVT is a loaded 50-mile road test which tests the complete operation of the truck from the driver’s point of view. The same product auditors perform the

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APA, DVT and EOL customer perception audits. Also, the same feedback process is used to feed information back to the team level. The main benefit of the APA process over the other external feedback loops is the timeliness of the information. The APA gives immediate feedback from the customer’s perspective to the teams. The TOS is clearly working for the plant. The hours per unit to build a truck has decreased about 20% since 2008, and warranty costs are approximately one-third of what they were two years ago. In addition, DTNA has a corporate auditor who conducts three unannounced quality audits per year. CTMP’s scores have improved about 75% from just a few years ago.

Associates award and reducing warranty costs. Of course, those goals cannot be achieved without some forethought. Each year the plant puts together a tactical implementation plan (TIP). TIP has been created for safety, quality, delivery, cost morale and environmental. TIP sets forth the steps and timelines for initiatives to be improved or implemented. It also is used for accountability and indicates which areas may need additional resources. Another way that CMTP strives to hit its goals is that there is no hierarchy in its quality production meetings. Management’s inf luence needs to be transparent throughout the organization. “You have to want to improve more than you want to be right,” says Veronica Hobbs, continuous improvement manager.

CONTINUING QUALITY But quality does not stop just because a truck rolls out the door. The plant continues to improve using what it calls a Blue Sky initiative. The Blue Sky is the plant’s 5-year vision, which helps ensure that everyone in the organization is driving toward the same goals. Each year the plant measures itself to the Blue Sky to determine the improvements needed to achieve its vision. Some of the quality metrics targeted for improvement within the quality process include achieving zero defects, winning a J.D. Power and

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EMPLOYEE ENGAGEMENT No matter how good the process is, it is nothing without a team to buy into it and support it. Year after year, engaged, empowered and enthusiastic employees make the Quality Plant of the Year stand above the rest. It is the employees’ never-ending commitment and dedication that helps a company lead the pack. The day before Quality visited CTMP in January, the finish cab line went down. Rather than wait an estimated three hours for the system to be back

online, employees manually pushed the Freightliner trucks off the line to keep production moving. The employees seem to understand that they are part of something special and, McCurry says, “The enthusiasm in the plant is infectious.” Employees are truly empowered. Last year the 1,000 production workers suggested almost 12,000 improvements, 85% of which were self-implemented. Most of the production workers have been at the plant an average of 18 to 20 years, and turnover is less than 1%. “Most of the people in this plant really enjoy dealing with the customers,” Harris says. He adds that the production workers are not afraid to go up to the customers visiting the plant and ask, “How can I do it better?” Smith adds, “Mike [McCurry] has said it before, the employees on the floor can sell a truck just as well as the dealership.” As with many companies, the economy affected the Freightliner plant. Today the plant runs on a single shift, considerably less than in its heyday of three shifts. Despite the economic conditions—or because of it—employees made a record number of donations to the United Way this past year. The employees realized that the donations were helping their own. McCurry likens it to the largest “family business” out there. A family business that anyone would be proud to be part of. Q

March 2011 | QUALITY

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CA SE ST U DI ES

 Automation has reduced Kellermann’s costs for the near- and long-term. Source: Vero UK Ltd.

AUTOMATION IN PROCESS

Palletized

Production Reduces Lead Times G

erman toolmaker Formenbau Kellermann GmbH (Neumarkt, Germany) reduced lead times by more than 20% after investing in VISI software and installing a palletized production process with a zero-point clamping system. The company was founded in 1970 by Heinz Kellermann and has become a sought-after partner in the automotive industry, providing single-and multiplecomponent tools for plastic parts such as intake manifolds, oil modules, air filter housings and cylinder head covers. Having relocated and expanded twice, the company is now run by graduate engineer Sabine Kellermann and currently employs 27 people. “Pricing pressure, competition from emerging countries and the trend toward ever shorter project terms are challenges that force tool manufactur-

ers to rethink the classical form of single item production,” Kellermann explains. “In toolmaking, flexibility and the use of the latest technology is a must. This basic principle also is applicable to Formenbau Kellermann, where we have invested heavily in machinery and software so [that] we are ready to adapt to changing market conditions.” The milling and electrical discharge machining (EDM) departments are equipped with two HPM1350 U and HPM 1850 U 5-axis milling centers from Mikron/AgieCharmilles, and one 5-axis Huron EX machine. In addition, there is a Mikron HSM 700 milling machine for electrode production, an AGIE 100 wire EDM machine, three vertical eroding machines (Exeron, Hansen), as well as manually operated machines for additional milling, drilling and grinding operations.

Process automation is a specialty of Formenbau Kellermann and it starts with tool design. Areas which are not directly involved in the design also are standardized to the greatest possible extent. Components such as pressure plates or guides are uniform in all tools. In the case of die centering, only two to three different sizes are used. In addition, there is an in-house company standard for design, as well as a standard component catalog. The computer automated design/ computer automated manufacturing (CAD/CAM) software of choice at Kellerman is VISI from Vero Software (Gloucestershire, England). “As a progressive company, we had already invested much earlier in 3-D,” Kellerman explains. “Prior to our switch to VISI in 2003, we worked with ICEM DDN, a product that had been on the market for many years but could no longer compete with modern systems.”

FEATURE RECOGNITION DRIVES CAM CONSOLIDATION In 2004, the company’s North Carolina department was equipped with VISI machining, where the CAM tasks were shared with PowerMILL from Delcam. However, in 2009 the company switched entirely to VISI for all machining activities. “The advantages of a uniform, consistent CAD/CAM system outweighed the benefits of dual products,” Kellerman notes. “Typically, we deal with short programming times, and feature recognition from native CAD data is an important component of our automation strategy.” The introduction of compass technology for feature recognition means that Kellermann automatically generates two and two-and-a-half-axis com-

BENEFITS  The consolidation of software and machinery has reduced lead times by more than 20%.  The ability to automatically convert three-axis to five-axis continuous toolpaths reduces programming time and still enables five-axis machining.

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QUALITY | March 2011

 Compass technology for feature recognition helps Kellermann to automatically generate two and two-and-ahalf-axis computer numerical control (CNC) programs for regular geometries, which reduces programming time and eliminates potential positioning errors.

www.qualitymag.com

puter numerical control (CNC) programs for regular geometries, including common toolmaking features such as holes or milling grooves. This dramatically reduces programming time and eliminates potential positioning errors. In principle, only three steps are necessary for CNC plate programming: Start the feature recognition, run the company-specific compass based rules and verify the completed CAM programs. The set up and customization of the Compass rules was performed by VISI distributor Mecadat GmbH (Bavaria, Germany), where on-site assistance was provided to analyze the existing CAM strategies and transfer this knowledge to the rules database.

THREE-TO-FIVE-AXIS SIMULTANEOUS MILLING One function that is used intensively at Kellermann is the ability to automatically convert three-axis to five-axis continuous toolpaths. “This enables us to reduce expenditures on programming time and still benefit from the advantages of five-axis machining,” Kellermann says. “For example, the Mikron HOM 1350U allows for an approach angle from 16 degrees to -120 degrees, whereby the distance between spindle and table is only 30 millimeters. This approach is applicable for most geometries and we benefit from better surface finish through the use of shorter, more rigid tooling and reduced vibration.

A palletized and zero-point clamping system lends flexibility to the production process. Source: Vero UK Ltd.

“Automated and standardized processes also require the efficient supply of information,” Kellermann continues. “The possibility of sharing the tool library from VISI was an important milestone for our automated processes. For example, all tooling databases are available to all users across the network and contain information typically seen in expensive tool-management systems such as toolholders, extensions, collets, cutting tools, including assemblies as well as their individual cutting conditions.”

REDUCING COSTS WITH AUTOMATION “There is rarely something that we cannot mill and we no longer experience bottlenecks on the CNC machines,” says Kellermann. The five-axis Mikron machining centers are equipped with a palette system that includes three round tables that can each be loaded with one ton

and intelligent zero-point clamping systems, which ensure highly optimized use of the CNC machinery. Kellermann also recognizes the flexibility advantages of a palletized and zero-point clamping system. “A running process can be interrupted at any time, without losing the zero-point,” she says. “This can be particularly useful in case of urgent repairs, or when spotting surfaces must be quickly re-milled, all which affect lead-time and efficiency.” Kellermann notes that the consolidation of software and machinery has reduced the company’s lead times by more than 20%. “Those who stand still have no chance in toolmaking over the long-term,” she says. “Automation has reduced our costs now and will continue to do so in the future.” Vero UK Ltd. +44 (0) 1242 542040 www.vero-software.com

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March 2011 | QUALITY

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CA SE ST U DI ES

 As an initial part of the error-proofing process, Donnelly shares scientific research with its employees to show why mistakes happen and then begins to examine jobs for opportunities to reduce error. Source: Donnelly Custom Manufacturing

Error

Proofing Your Staff

With the right processes in place, human error can be eradicated.

C

ompanies have increasingly come to rely on lean manufacturing practices to improve efficiencies in their operations. Yet, without ongoing initiatives, such practices can fall short—particularly in terms of mitigating human error. Human inspection of parts is often not completely effective. Companies are challenged not just to catch the defects caused by mistakes employees make, but to prevent them from occurring in the first place. According to

2010’s Quality Handbook, Sixth Edition: The Complete Guide to Performance Excellence, 100% human inspection of parts is only about 80% effective. The challenge for companies, then, is not to catch the defects caused by mistakes employees make, but rather to prevent them from occurring in the first place. Error proofing, a lean technique used by Donnelly Custom Manufacturing Co. (Alexandria, MN), has proven effective in doing just that. The company specializes in short-run

injection molding of complex thermoplastics for industrial original equipment manufacturers (OEMs) who sell end-products in lower unit volumes. Unlike common mistake-proofing techniques that focus on the design phase or the manufacturing processes, Donnelly’s error-proofing methodology focuses on the people, particularly on the mindset needed to implement plant-wide error-proofing techniques. It teaches employees how to take preventative measures that decrease the defects caused by errors.

THE WHYS AND HOWS OF ERROR PROOFING Because of the complexity of its business, Donnelly continually seeks out technology advancements and new strategies to improve its productivity and quality. Still, the company faces the inevitable challenges of human error. For that reason, Donnelly chose to apply lessons it learned from the Training Within Industry (TWI) Institute, a program that teaches employees how to improve interoffice relations, problem solving and accuracy. Donnelly created and implemented an error-proofing workshop where employees brought in workplace problems they had encountered that could be addressed with error proofing. Much like TWI, which prepares supervisors to train employees to solve problems, Donnelly’s error proofing teaches employees to be problem identifiers and solvers. The first step in the error-proofing process is to help employees establish the right mindset about making

BENEFITS  Applying the new error-proofing process to several of its customers’ jobs reduced Donnelly’s parts rejection associated with human error by 75% year-over-year.

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QUALITY | March 2011

 Donnelly implemented a countermeasure to address inconsistencies in its production process, which audits have revealed to be 100% effective.

 By using error proofing, Donnelly reduced its parts-per-million defect measures by two-thirds.

www.qualitymag.com

mistakes. Donnelly helped employees understand their own weaknesses by educating them about human behavior. Donnelly shared a 2008 study from researchers at the University of Bergen, Norway and the behavioral neuroscience department at Georgia State University that explains that human error is the result of periodic, minor glitches in the brain. When recording brainwaves, scientists can detect these glitches and accurately predict mistakes up to 30 seconds before they happen. Presenting such material to employees is intended to help them approach the error-proofing process with understanding. When everyone is on the same page, employees must then examine defects caused by mistakes to isolate problems and develop potential solutions. Together, employees brainstorm ideas and rank each potential solution according to the speed, complexity and cost of implementing it, as well as its anticipated effectiveness. Finally, employees evaluate the solutions and provide their cost/ benefit recommendations to customers, who select the one that best meets their needs. Donnelly employees then apply the chosen countermeasure to rectify the mistake. The goal is to determine and select the easiest, lowest cost and most effective solution. Periodic audits help ensure that the countermeasures are effective and enduring.

in the process: employees periodically forgot to load inserts into their molds, and they occasionally placed inserts in backwards. Together, a team of employees identified 12 different solutions to the problem and ranked them according to cost, speed of implementation and potential effectiveness. The result? Donnelly, in conjunction with the customer, opted to put sensors in the mold that could detect if the insert was in place and would stop the press if it was absent. While this solution required some investment on the part of the customer, it eliminated the risk of a more costly part failure later. Secondly, to prevent the insert from being placed in the mold backwards, Donnelly designed and built the pickouts to hold the inserts so that they could only be placed into the mold in the correct direction. The company also has implemented periodic audits to ensure the counter-

measure is being used properly and to measure the success of the solutions. Thus far, the audits indicate the solution has been 100% effective. While error proofing takes time to implement, the benefits to Donnelly’s productivity and quality are well worth the effort. Error proofing empowers employees to use their knowledge, experience and creativity. At its core value, error proofing encourages employees to do their best and eliminates barriers that may otherwise prevent them from taking pride in the work they do. It also builds a sense of trust, encouraging teamwork and respect. The end result is employees who are more committed and motivated, and make a better quality product. TWI Institute Liverpool, NY (315) 412-0303 twi-insitute.com

REAL SOLUTIONS, REAL PROBLEMS Donnelly originally established its error-proofing workshop to address quality issues that occurred with one of its longtime customers. Close analysis pointed out a common cause: mistakes due to human error. Applying the new error-proofing process to several of this customer’s jobs reduced parts rejection associated with human error by 75% year-over-year and reduced parts-per-million defect measures by two-thirds. Since then, Donnelly has continued to implement error proofing for other customers in multiple jobs. One recent success involved a mold requiring multiple hand-loaded inserts. Two mistakes were occurring

www.qualitymag.com

March 2011 | QUALITY

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QUALITY | March 2011

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INSPECTION SOFTWARE PowerINSPECT is hardware-independent inspection software with inspection routines for taking simple measurements, inspecting geometric features and analyzing complex 3-D surfaces. It has point, wireframe and surface export for measured entities, the ability to inspect along the edge of a part and alignment for complex freeform shapes. DELCAM (877) 335-2261 WWW.DELCAM.COM

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QUALITY | March 2011

ERROR COMPENSATION SYSTEM The MAG volumetric error compensation (VEC) system can analyze and correct positioning errors in all machine-tool axes simultaneously. It reduces the time to determine needed error compensations from days to hours, and integrates both linear and rotary axes into the tool point compensation process. It was designed to improve machining accuracies for large machine tools needed to produce large and complex-shaped parts. MAG (425) 880-6869 WWW.MAG-IAS.COM

DIGITAL OPTICAL COMPARATOR The VisionGauge digital optical comparator is aligned in a vertical configuration. Its parts are mounted flat on the system’s XY stage and the lens looks down on the parts. This model has the same standard options as the horizontal configuration, including reflected illumination, a laser module for Z-axis measurements, motorized rotary fixtures and a fifth monitor. METHODS MACHINE TOOLS (978) 443-5388 WWW.METHODSMACHINE.COM

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DATA LOGGING SYSTEM

ANALYTICAL SOFTWARE

3-D SCANNERS The Gomatos Triple Scan series of 3-D scanners has blue LED light source technology and new pattern projection techniques. The scanners measure shiny and dark colored surfaces, difficult to capture areas, automatic scan patch geometry based alignment, intelligent software providing data quality checks, measurement history and parametric based inspection capabilities. CAPTURE 3D (714) 546-7278 WWW.CAPTURE3D.COM

STATISTICA 10 is the newest version of the analytic software and has 64-bit CPU technology and highly optimized multithreading. The software’s functions are optimized using advanced multithreading technology so that they can take advantage of multiple cores or processors. It is integrated with Microsoft Sharepoint, so documents can be checked in and checked out of SharePoint from within the operator interface. STAT SOFT (918) 749-1119 WWW.STATSOFT.COM

The LogMessage system was designed to record data for applications such as remote monitoring, product testing, quality and reliability testing, process monitoring, research and development, and fault analysis. It is available in seven configurations that incorporate up to 30 analog inputs with a sampling rate up to 1,200 hertz. It can measure voltage, current, thermocouple or RTD sensors and has 1 gigabyte of internal memory to record up to 128 million data points. CAS DATA LOGGERS (800) 956-4437 WWW.DATALOGGERINC.COM

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March 2011 | QUALITY

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PAGE

WEB SITE

Automated Precision Inc.

55

www.apisensor.com/domore

Bal-tec Division, Micro Surface Engr. Inc.

48

www.precisionballs.com

Bruker Nano Inc.

15

www.bruker-axs.com

Carl Zeiss

29

www.zeiss.com/metrology

Creaform

45

www.creaform3d.com

CyberMetrics Corp.

BC

www.cybermetrics.com

DNV Certification

10

www.dnvtraining.com

Dorsey Metrology International

37

www.dorseymetrology.com

Epsilon Technology Corp.

50

www.epsilontech.com

Euro-Tech

51

www.eurotechcorp.com

Faro Technologies Inc.

33

www.faro.com

Gagemaker Inc.

41

www.gagemaker.com/quality

GE Sensing & Inspection

2

Gradient Lens Corp.

48

www.gradientlens.com

Hexagon Metrology Inc.

21

www.hexmet.us

5

www.hommel-etamic.com

Hommel-Etamic America Imada

63

www.imada.com

Intelex

53

www.intelex.com/quality

LaVezzi Precision Inc.

61

www.lavezzi.com

Ledford Gage Lab

63

www.ledfordgage.com

Mahr Federal Inc.

1, 44, 49

www.mahr.com

Mark-10 Corp.

7

www.mark-10.com

Micro-Vu Corp.

25

www.microvu.com

Mitutoyo America Corp.

IFC

www.mitutoyo.com

NSF International

26

www.nsf-isr.org

Olympus/Innov-X

11

www.innovx.com

Origin Technologies Corp.

39

www.origintech.com

Q-Das

35

www.q-das.com

QMI-SAI Global

12

www.qmi-saiglobal.com

R & R Sales LLC

39

www.cmmfixture.com

Renishaw

38

www.renishaw.com

9

www.stindustries.com

S-T Industries Inc. Scienscope

59

www.scienscope.com

Shimadzu Scientific Instrument

43

www.ssi.shimadzu.com/testing

TE-CO

62

www.te-co.com

Tinius Olsen Testing Mach Co.

49

www.tiniusolsen.com

United Testing

44

www.unitedtesting.com

Verisurf

42

www.verisurf.com

VisionX Inc.

13

www.visionxinc.com

Webster Instrument Inc.

50

www.webstertesters.com

Werth Messtechnik GmbH

61

www.werthinc.com

Western Gage Corp.

62

www.westerngage.com

Yxlon International

31

www.yxlon.com

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

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

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March 2011 | QUALITY

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VISION & SENSORS

TA B L E O F C O N T E N T S

March 2011 21VS

DEPARTMENTS 4VS Editor’s Note Spring Fever 6VS Industry News 8VS Integration Corner

Cloud Computing: The Next Software Architecture for System Integration 10VS Machine Vision 101

CCD vs. CMOS 24VS Application

Scanning for Safety 26VS Products IBC Advertising Index SOFTWARE

14VS Universal Software Strengthens Production Quality The quality and quantity of vision algorithms available today are greater than before.

IN THE NEXT ISSUE GigE Interface Color Analysis Integration

SENSORS

18VS Measurement Sensors Go the Distance in Manufacturing Short-range distance measurement sensors offer high accuracy without contact, require no calibration and provide simple programming.

ABOUT THE COVER March 2011

www.visionsensorsmag.com

Measurement Sensors Go the Distance in

Manufacturing p. 18VS

LENSES

21VS Transform Single-Use Lens Designs Clever features and proprietary techniques can transform a single-use design into a multipurpose solution.

Universal Software Strengthens Production Quality p. 14VS | Transform Single-Use Lens Designs p. 20VS

S Short-range distance measurement sensors m aare used in automottive, packaging, machining, robotics, m ttooling and generaally all manufacturing aareas. Source: Sick

VISIT VISION & SENSORS ONLINE AT

www.visionsensorsmag.com Automatic Quality Controls Ensure Cars Produced at Ford Genk Work Perfectly

2VS

VISION & SENSORS | March 2011

www.visionsensorsmag.com

Teledyne DALSA Smart Cameras are ideal for Color/Mono applications: t Packaging - Bottle cap color and label confirmation t

1IBSNBDFVUJDBM - Verify pill count and color in blister pack t Automotive - Inspect color or texture of interior parts - Verify order of color wires in harness t General Machine Vision

Smart Cameras

Teledyne DALSA are designed and ruggedized for harsh environment factory floor deployment and are truly exceptional all-in-one intelligent vision systems. BOA has a tiny form factor, easy mounting capabilities and has an IP67 rating.

Multiple processing engines combine DSP, FPGA and CPU technologies.

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Embedded point-and-click software - easy to use & nothing to install.

VISION & SENSORS

FROM THE EDITOR

Spring Fever “Spring is when you feel like whistling even with a shoe full of slush.” — Doug Larson March is my favorite month (and not because my birthday falls during it). Although that’s certainly a perk, what really makes this month stand out for me is the anticipation of spring and what follows after: summer. As a Chicagoan, the winters are long and I spend months hibernating in my home as snowstorm after snowstorm touches down. In this case, I should probably say “blizzard”, seeing Manufacturing that last month our city was hit with a massive winter storm that delivered more than 20 inches of snow, making it the third largest snowfall in Chicago history. Ironically, the blizzard fell on Groundhog Day when trusty groundhog Punxsutawney Phil came out of his burrow only to see no shadow. Tradition says this signifies an early spring. While the prediction accuracy rate for this furry rodent is only 39%, according to the National Climatic Data Center, which some of you may agree is pretty bleak, I’ll take what I can get at this point! With that said, this is a month of expectations. What is your outlook for the year? Perhaps you attended the Automated Imaging Association (AIA) Business Conference in January to gain some industry insight. Or maybe you went to learn about new technology trends that your business might benefit from. March 2011

While I was not in attendance, vision integrator Ned Lecky, a regular columnist and member of our editorial advisory board, attended the conference and shared some of his thoughts. “I think there was a very business-as-usual mood at the conference. There is growth in many key industries, while other ones are flat,” Lecky says. “As always in business, we look for the high-growth opportunities and work at getting into position to capitalize on them, and nimbly avoid the time and money sinks or lowvolume opportunities.” Lecky also talked about how the machine vision industry was spoiled in the 1990s, when high-margin opportunity was available in just about any factory where production was ramping up. It wasn’t possible to overspend on technology. However, he adds that when the 2000s hit, a very painful slap of reality caught many companies off guard. There was uncertainty about how to leap from one market to another, and so companies would get scared and bypass opportunities. Now in the United States, Lecky says the successful companies understand that nothing is

www.visionsensorsmag.com

Measurement Sensors Go the Distance in

p. 18VS

Universal Software Strengthens Production Quality p. 14VS | Transform Single-Use Lens Designs p. 20VS

certain; everything is in play. You look for partnerships, joint-development opportunities and product development plays that can create volume opportunity for your company, irrespective of global trends, industry trends and general malaise. Is your company designing new products for industries that are recession-proof? What are your expectations for the coming year? Will you be attending any upcoming events to gain further investment strategies for your business? If you didn’t get a chance to attend the AIA Business Conference, next month is the Quality Conference, to be held April 11 to 13 in Charlotte, NC. Join us and other industry professionals to learn more about test, inspection, measurement and evaluation practices in manufacturing. This event will deliver education through case studies and hands-on examples to help you develop your skills. You can register for this event at www. qualitymagconference.com. As Mother Nature starts to calm down here in the Windy City, I am looking forward to a month of possibilities.

Kari O’Rourke, Managing Editor

Vision & Sensors Editorial Advisory Board David Dechow Aptura Machine Vision Solutions

4VS

VISION & SENSORS | March 2011

Ned Lecky Lecky Integration

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VISION & SENSORS

NEWS

Teledyne Completes

Acquisition of Dalsa THOUSAND OAKS, CA and WATERLOO, ONTARIO, CANADA—Teledyne Technologies Inc. and Dalsa Corp. jointly announced the successful completion of the previously announced plan of arrangement (the “Arrangement”). The Arrangement was completed following the approval of the Ontario Superior Court of Justice (Commercial List) and satisfaction of the various conditions precedent to the Arrangement.

MACHINE VISION MARKET CONTINUES SOLID GROWTH IN NORTH AMERICA ANN ARBOR, MI—Sales of machine vision components and systems in North America rose substantially in the third quarter of 2010. Overall, year-over-year growth hit 68%, up from second quarter 2010 at 60% and fi rst quarter 2010 at 34%, according to the new sales tracking report of the Automated Imaging Association (AIA). The new report, titled Quarterly Machine Vision Sales Tracking Report, showed that sales were robust in all major machine vision supplier markets, including cameras, lighting, optics, imaging boards, software, application-specific machine vision systems and smart cameras. The new report also disclosed that 68% of companies submitting data for the report expect sales to improve through fi rst quarter of 2011. Of the remaining companies, 28% anticipate sales at or near the level reached in the third quarter, and just 4% believe that sales will decrease. “These results are very impressive, leaving little doubt that the recovery in the North American machine vision market is real and sustainable,” notes Paul Kellett, AIA’s director of market analysis. “Based on industry expectations, we expect the recovery to continue at least another six months,” Kellett adds.

XENICS OPENS U.S. SUBSIDIARY BEVERLY, MA—Xenics, a manufacturer of infrared detectors and customized imaging solutions, has established Xenics USA Inc.

6VS

to broaden its market presence in North America. The office, located near Boston, is headed by Luc DeBrouckere, who has 35 years of managerial and technical experience in IR imaging. Besides serving industrial customers, Xenics USA is positioned to better penetrate the strategically important and rapidly growing market for security systems, as well as the thriving institutional and OEM markets for governmental projects. The product spectrum marketed and supported by Xenics USA, which is a subsidiary of Leuven, Belgiumbased Xenics nv, will include all products and solutions in the company’s broad-based product portfolio.

ANDOR LAUNCHES SCIENTIFIC IMAGING COMPETITION BELFAST, NORTHERN IRELAND—Andor Technology, specialists in scientific imaging, spectroscopy solutions and microscopy systems, has launched the second Andor Insight Awards 2011 scientific imaging competition. Now in its second year, the competition rewards visually stunning and scientifically captivating images, spectra, graphics and movies. The competition is open to entries produced with Andor equipment regardless of technique or application. Researchers can submit their entry into one of two categories: physical sciences or life sciences. The winner of each category will receive an Apple iPad and benefit from significant publicity of their work throughout a range of scientific publications.

VISION & SENSORS | March 2011

“Last year’s competition highlighted the depth of cutting-edge research carried out with Andor products and systems by researchers all over the world,” says Donal Denvir, Andor’s technical director and Insight Awards jury member. “We look forward to rewarding more visually stunning and scientifically captivating entries through this year’s competition.” The deadline for this year’s awards is May 31, and contestants can submit an unlimited number of entries. The winners will be announced at the end of July. First place for the 2010 Insight Awards was shared between Dr. Neil Ganem, Dana-Farber Cancer Institute, Harvard Medical School and Professor Mihalis Mathioudakis and Dr. David Jess from the Solar Physics Group at Queen’s University, Belfast.

FAIRCHILD IMAGING TO BE ACQUIRED BY BAE SYSTEMS ARLINGTON, VA—BAE Systems has entered into a definitive agreement to acquire Fairchild Imaging Inc. (Milpitas, CA), a company specializing in solid-state electronic imaging components, cameras and systems for aerospace, industrial, medical and scientific imaging applications. BAE Systems currently owns 8.7% of the equity of Fairchild Imaging and, upon completion of the acquisition for a cash consideration of approximately $86 million, will have acquired all of the remaining outstanding equity. Upon closing of the acquisition, Fairchild Imaging’s staff in Milpitas will become part of BAE Systems’ Electronic Solutions sector, headquartered in Nashua, NH. The proposed acquisition of Fairchild Imaging follows BAE Systems’ acquisition of OASYS Technology in 2010. OASYS Technology specializes in the design and manufacture of electro-optical systems and subassemblies for aerospace, defense, industrial and commercial markets.

www.visionsensorsmag.com

The acquisition is conditional, among other things, upon receiving certain regulatory approvals and is expected to close in the fi rst half of 2011.

SONY APPOINTS ASIO VISION AS ISRAELI INDUSTRIAL CAMERA DISTRIBUTOR ISRAEL—Sony Europe’s Image Sensing Solutions (ISS) division has announced the appointment of Asio Vision as an official industrial camera product distribution partner in Israel. Asio Vision has become the only Israeli distributor with the rights to sell Sony ISS’ extensive portfolio of industrial camera modules to its partners in the region. Technology covered by the agreement includes Sony ISS’ machine vision and visual communications product ranges, including SmartCamera, GigE, EVI, micro-XCD and FCB cameras. Matthew Swinney, senior product marketing manager, Sony Image Sensing Solutions commented, “Asio Vision’s founders bring extensive in-house experience of the Israeli industrial camera market. Being a young company, they also bring a fresh approach and we’re looking forward to working with them to deploy our innovative camera technology.” Asio Vision will begin supplying Sony cameras immediately.

COAXPRESS STANDARD APPROVED TOKYO, JAPAN—The Japan Industrial Imaging Association (JIIA), host of the CoaXPress high-speed digital interface standard for imaging applications, announced that the fi rst edition of the standard has been overwhelmingly approved by its Working Group as a JIIA standard for public release. Additionally, the AIA/EMVA CoaXPress Liaison Group which consists of members from the Automated Imaging Association (AIA) and the European Machine Vision Association (EMVA), have also given their approval, paving the way for global adoption in early 2011.

www.visionsensorsmag.com

Representatives from both groups voted on the standard during the past month and the results were released in December 2010, showing a total of 31 votes in favor, none opposed and two abstentions. JIIA also announced the launch of a compliance test procedure to test and approve CoaXPress devices as officially compliant products. This compliance program will also manage permission to use the CoaXPress name and logo. Additional details of how this process will work will be announced in Q1 2011. Following this successful ratifi cation of the standard, the CoaXPress specifi cation will now go through a three-month international appeal process, during which interested parties can comment on a wide range of technical and legal areas. The result of this process, which has been agreed upon by JIIA and the two other major industry organizations—the AIA and the EMVA, will be announced at Automate 2011 in Chicago and will pave the way for CoaXPress to become an international standard.

EDMUND OPTICS CREATES INNOVATION AWARD BARRINGTON, NJ—Edmund Optics, a provider of optical components, has created the Edmund Optics European Research and Innovation Award to support research and innovation in the field of optics and imaging at universities and non-profit research institutions located in Europe. The company encourages students, PhD candidates, lab managers, teaching assistants and lecturers working on research programs that both utilize and develop optical technology to apply for its award. Edmund Optics intends to sponsor relevant research projects with product donations. In addition, the company will invite the three winners to Vision 2011, a trade show for the imaging and vision industry held in Stuttgart, Germany, in November 2011.

Applications will be reviewed internally by Edmund Optics experts and selected according to technical merit and innovative application of optics in the respective research projects, with a particular emphasis on the life quality improvement aspect of the presented projects. The winners will be announced during October 2011. “Optic technology helps us to respond to the challenges we are currently facing in biotech, energy efficiency, security and communications,” said Dr. Thomas Kessler, Edmund Optics executive vicepresident of global sales. “The Edmund Optics European Research and Innovation Award intends to recognize scientists and institutions, to highlight their work, and to actively contribute to the development of their projects.”

ALLIED VISION TECHNOLOGIES ACQUIRES VDS VOSSKÜHLER STADTRODA, GERMANY— Allied Vision Technologies (AVT), market leader for digital industrial cameras with Gigabit Ethernet and FireWire interfaces, has acquired 100% of the shares of the camera producer VDS Vosskühler (Osnabrück, Germany). Effective immediately, the acquisition increases AVT’s portfolio by the addition of near infrared (NIR) and long wave infrared (LWIR) camera technologies, as well as extensive competencies in the area of active camera cooling. The acquisition further strengthens the overall market position in the area of industrial cameras. Incorporated in 1985, VDS Vosskühler develops, produces and markets industrial cameras and charge-coupled device (CCD) cameras for visible light. Herein, VDS concentrates in customer-specific variations for OEM customers. Through the acquisition, AVT—an affiliate of the technology company Augusta Technologie AG—gains immediate access to these technologies and increases its customer base substantially.

March 2011 | VISION & SENSORS

7VS

VISION & SENSORS

I N T E G R AT I O N C O R N E R

My company regularly develops integrated vision and motion control software for a wide variety of applications in factory automation and transportation inspection. Many of these applications require a fairly complex but clean, easy-to-maintain graphical user interface (GUI). There are many technologies for implementing GUIs, and different companies have various favorites at different times. Certainly, Microsoft Visual Studio.NET, Microsoft VisualBasic, Java and National Instruments LabView leap immediately to mind. For us, as with many integrators, a primary area of concern is code portability. We deploy our machine vision libraries on Windows, Linux and embedded OS platforms with relative ease by sticking to standard C and C++ constructs and by using as little assembly language as possible. This is fairly straightforward and results in better code anyway. However, the transportability of GUI code is much more difficult to achieve. We often use Microsoft.NET or VB, but this results in a very Windows-centric architecture. We have tried Qt—a cross platform windowing system from Nokia—as well as gtkWidgets, another X-windows/Windows cross-platform GUI builder that

8VS

has many adherents. Each of these approaches, however, requires the adoption of a single-vendor solution that is by no means future-proof. The risks of developing applications that get orphaned and are hard to maintain or upgrade in the future are large. The answer came to me in December. Like many companies, we have a heterogenous mix of Windows PCs, Linux PCs, Macs, iPhones, Blackberries, Droids—a bit of an Inferno-esque networking challenge. We were lost in the weeds of Mail, Entourage, Outlook, Thunderbird and Gmail, and I asked our IT consultant to help pick the best mail client. And the answer was too simple. The only good mail client is no client. Make it all work in your browser, which is best done by Google with its GoogleApps and GoogleDocs systems. Everything is out there, including the applications, and one can access them equally easily from anywhere as long as one

VISION & SENSORS | March 2011

By Ned Lecky

has something with a CPU, a keyboard, a screen and a browser. Within a week, we had migrated the whole company to GoogleApps and GoogleDocs, and we have been more and more productive, and not discussing IT issues, ever since. What does this have to do with system integration software? Well, here’s the Eureka moment: Just as the only good mail client application is none, the only good any-kind of client application is often none. And cloud computing makes this possible. How? Well, cloud computing works like this: All of the data lives on servers in professionally managed server farms, and Web apps, which are designed to run in your browser, are transferred to your browser as needed. Now, the capabilities of those browser-based apps are formidable. Explore the GoogleApps document editors, for text, spreadsheet and presentation applications, for example. These apps are beginning to rival the PC-based apps available in Office, and require no code on a client machine other than a browser. How far can we push the browserdriven app? They go all the way. The key is the emerging HTML5 standard, a description of what capabilities browsers provide and how they are told to do different things. It turns out that in HTML5 one can design a program as complex as a word processor or a spreadsheet program, and the HTML5 code that is sent to the browser fully specifies the application. The amazing thing is that this same HTML5 works just fine on a Windows PC in Explorer, or on a Mac in Safari, or on any machine in Firefox, or on an iPad, or in mobile Safari on an iPhone, or on an Android—automatically. In addition, the new generation of programmers are usually more than a little adept at creating these Web applications— a key portion of their training and experience is in this area. What about performance? My company writes image processing

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applications. We regularly crank through three-million-pixel images at 10 frames per second and are reading characters, counting objects or measuring features. However, HTML5 and browsers are powerful enough to run video games now, and video games are basically machine vision in reverse—they place most of the same kinds of burdens on CPUs as do image processing or intense motion control applications. Therefore, if you can make a three-dimensional (3-D) game run on it, you can pretty much do anything on it. In fact, if you want to hire a programmer who knows tons about optimization, matrix math and high-speed number crunching, you should probably be interviewing game developers. I do. What about data transfer volume? A cloud-computing, Web-centric model often is discarded by companies based on an uninformed analysis of the data transfer requirements. In image processing applications such as the ones my company creates, we may be transferring dozens of megabytes per second each from five or 10 cameras. The notion of passing all of this data up to a central server in the sky for analysis is indeed impractical. However, this also is not required. Remember, the HTML5 code and scripts are running locally on the client machine. They can access the image or other application data directly without transferring it over the network. The pixels, or any other real-time data, never need to leave the browser, and any hardcore num-

ber crunching libraries will be downloaded to the client PC browser, too. What about security and reliability? These are other common concerns based on the misplaced idea that all of the data will have to be transferred over a public network, or that multiple computers need to be functioning to make the application work. In fact, the entire “server” need not actually be many states away out in the real cloud. It can be a machine residing within the walls of the customer, or can even be on the exact same machine that is running all of the data analysis in the browser app. In this latter architecture, we still have a single PC solution, but have architected it in a cloud-computing fashion and with cloud-computing tools so that it is consistent, portable, general purpose and automatically improving as computers and browsers advance. So watch for cloud-centric apps in factory automation and integration over the next few years. In portability, general performance, and the availability of strong programming talent, this is the way to design new systems. While this idea is pretty new for factory automation and machine vision applications, the trend is inescapable and the capability is there. Ned Lecky is the owner of Lecky Integration (Little Falls, NY). For more information, call (518) 2585874, e-mail [email protected] or visit www.lecky.com or his blog at www.visionsensorsmag.com.

Call Sunny Coverly at (610) 932-8350, or FAX: (248) 283-6587 www.visionsensorsmag.com

March 2011 | VISION & SENSORS

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M A C H I N E V I S I O N 10 1

CCD vs. CMOS

For a variety of technical reasons, CMOS sensors in the past were considerably less efficient at converting incoming light into an THERE ARE SMALL DIFFERENCES ALONG THE WAY FROM LIGHT electrical signal. The photosensiTO A SIGNAL. By Valeria Mix and Dr. Joachim Linkemann tive area within each pixel in a CMOS sensor occupies only a fractional part of the total pixel area. The rest of the pixel area was populated by the individual readout electronics associated with each photosensitive area. The structure of CCD sensors is different. In CCDs, the electronics for the evaluation of the charges collected by the sensor surface is located outside of the chip, so almost the entire chip surface is available for photosensitive structures. Over the past few years, design improvements have increased the size of the light sensitive area of CMOS sensors to near the level of CCD sensors. One example of such an improvement is the microLeading camera manufacturers are now including both CCD and CMOS lens array that is now applied sensors into their product family to the CMOS chip. The lens lines. Source: Basler AG array collects the light impinging on each pixel area in sensor and Due to constant improvement and optimization over focuses it on the available light senthe years, today’s charge-coupled device (CCD) sensors sitive region within the pixel.

stand for excellent image quality. Originally developed in 1969 for the storage of data, the potential of the CCD as a light sensitive apparatus was soon realized. By 1975, the first sensors with a resolution sufficient for television cameras appeared. Complementary metal-oxide semiconductor (CMOS) sensors were invented around the same time, but until the 1990s, CMOS technology suffered from low lithography resolution and a lack of CMOS fabrication processes. With the advent of CMOS active pixel sensor (CMOS-APS) technology, these sensors were virtually reinvented. Since their introduction in the mid-90s, CMOS sensors have become the first choice for high-speed imaging. They not only exhibit superior performance

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regarding speed, but also typically have a lower price. Leading camera suppliers typically include both sensor technologies in several different camera types in their portfolio.

CONVERTING LIGHT INTO AN ELECTRICAL SIGNAL Both CCD and CMOS sensors are based on the same physical principles. They convert incoming photons into electrons by means of a photo effect. As a result of their sensor structure, the maximum sensitivity of CMOS sensors is in the red spectral region (650 to 700 nanometers). CCD sensors have a maximum sensitivity at about 550 nanometers—exactly where the human eye is most sensitive.

VISION & SENSORS | March 2011

THE PRICE OF INDIVIDUALITY One set of electronics for all pixels—this phrase regarding processing capability is valid for CCD sensors and at first sight—sounds rather like a trade-off. However, it is an advantage for image quality. Because there is one common electronic path for a large fraction, if not for all of the pixels in a CCD chip, all analog pixel signals are evaluated and processed in the same way, and they are all converted to digital signals in the same way. CMOS chips carry individual processing electronics on board each pixel and are different in this respect. This characteristic means that they can be read faster and that the image area can be accessed in more flexible ways.

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However, there are tiny variations within the individual electronic structures used to process each pixel, meaning that the signal offset can differ from pixel to pixel within a CMOS sensor, although the amplification slopes are almost identical. Variations between the offset values of the pixels in a CMOS sensor are typically 10 times larger than those of CCD sensors. Taken together, this offset variation represents a difficulty with respect to the sensitivity threshold of the sensor. This is particularly true when a weak signal that is slightly greater than the background noise must be detected. In this situation, a CMOS sensor looks worse than a CCD sensor. By definition, this threshold is reached when the signal from the sensor is as high as the noise, for example, the signal-to-noise ratio (SNR) equals one. A technical term that quantitatively describes this characteristic is known as the fixed pattern noise (FPN). CMOS sensors exhibit a higher FPN than CCD sensors.

the maximum SNR ratio equals the square root of the saturation capacity. Thus, the CMOS sensor excels in this area, but it needs more light to do so. As a simplified rule-of-thumb, one can say that CCD sensors are the preferred choice for applications with little light and CMOS sensors are a good alternative when there is a lot of light.

TOO BRIGHT FOR A SENSOR? If particularly bright light is present, operators must sometimes struggle with other effects. When a CCD pixel is overexposed to light, the pixels can generate an excess of electrons that can migrate into neighboring pixels. In this situation, very bright image structures seem to extend into the darker structures, an effect known as bloom-

Sensor Structure

LESS SENSITIVITY, MORE SPACE FOR ELECTRONS CMOS sensors, however, do score much better in another area—they can provide a higher full well capacity. The full well capacity represents the maximum number of electrons that an individual pixel can hold. On CCD sensors, this number is often artificially limited to a reduced saturation capacity to avoid certain technical problems. The ratio of the saturation capacity— full well capacity—to the sensitivity threshold determines the sensor’s dynamic range. In comparison to a CCD sensor, a CMOS sensor wins with regard to the saturation capacity what it loses when it comes to low-light sensitivity. As a result, CMOS and CCD sensors have almost the same level of dynamic range. In principle,

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March 2011 | VISION & SENSORS

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CMOS sensors are a good alternative when there is a lot of light. Source: Basler AG

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VISION & SENSORS | March 2011

ing. CMOS sensors do not see the migration effect and are not prone to blooming. After a CCD sensor has been exposed to very bright light, the charge transportation process can cause bright stripes to appear in the image. The bright structures within the image appear as white smeared lines. This effect is known as smearing and can be seen, for example, in images acquired at night when a car approaches the camera with its headlights on. As with blooming, CMOS sensors have an advantage compared to CCD sensors because they do not exhibit smearing. This explains why cameras equipped with CMOS sensors are often preferred for outdoor use.

THE AGONY OF CHOICE CMOS sensors have a shorter history than CCD sensors, but they are now technically mature and even represent the best choice for some applications. When one must choose the optimum solution of a specific task, many of the aspects mentioned will come into play. In the end, the constraints and the details of an application should determine which sensor technology represents the best alternative. Valeria Mix is technical writer and Dr. Joachim Linkemann is product manager at Basler AG (Ahrensburg, Germany). For more information, call +49 4102 463 500, e-mail valeria.mix@ baslerweb.com or visit www.baslerweb.com.

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AUTO RACKING IS EASY... WHEN YOU HAVE A VISION

Auto racking is a proven, cost-effective method to load and unload parts. We’ll customize a solution so you can: • Increase safety - No need to lift heavy parts • Improve quality - Place parts exactly where you need them • Speed up production - Quicker than manual loading and unloading • Reduce costs - No need to retool rack when product geometries change The Pepperl+Fuchs VMT group has over 20 years of success in applying turnkey 2D and 3D robotic vision-guided technology. With our easy-to-use test and calibration process along with multiple redundancies, uptime and reliability are assured. Download a free white paper that discusses how to successfully implement vision-guided auto racking at: www.sensing.net/autorack-i

Pepperl+Fuchs, Inc. Ann Arbor, MI 330.486.0001 www.sensing.net/autorack-i Quality Quick Clicks 338 at qualitymag.com

VISION & SENSORS

S O F T WA R E

Universal Machine Vision Software

software system’s comprehensive toolset to deliver flexible, custom solutions for solving complex manufacturing inspection challenges. Two tools available in advanced software sets that can prove useful for many applications are advanced pattern THE QUALITY AND QUANTITY OF VISION ALGORITHMS AVAILABLE find and optical character recogniTODAY ARE GREATER THAN BEFORE. By Steve Maves tion (OCR) tools. The advanced pattern find tools provide a solution for variably positioned part location, inspection and identification challenges. From robotic guidance to highspeed inspection of randomly orientated, scaled and located parts—with subpixel accuracy—a powerful pattern find tool elegantly solves hundreds of chalA pinpoint pattern lenging vision applications. find tool can be used to solve challenging Machine vision systems part location, inspeccommonly use a series of tion and identificaedge or binary large object tion applications. Source: PPT Vision (BLOB) algorithms to locate and inspect parts. By comparison, advanced pattern find tools use the edge information from an object to locate the part. Today’s machine vision software allows vision systems These advanced pattern find tools increased simplicity with to solve more complex and demanding applications. In deliver the power of using a single tool to fact, some smart camera software features more than adjust for variable location, rota120 vision tools and algorithms for building powerful tion and reflectivity. Another advanced vision tool is custom inspections, guidance and identification solutions. OCR. While OCR technology is not new, it can now allow for easier setup along with expanded capabiliHowever, these new capabilities prise, it behooves engineers to select ties, making it more accessible for often come with their share of initial a vision system with the necessary reading and verifying text for applisetup and maintenance complexity. capabilities, as well as a universal cations such as automotive, medical Further, many vision equipment software suite that operates the and plastics. manufacturers have multiple softsame on all smart camera models. OCR tools find character pattern ware platforms across their product matches from a library of taught lines, making programming various NEW VISION TOOLS characters, while optical character systems difficult—particularly when With improvements to image proverification (OCV) tools confirm application scope changes demand cessing technology, the quality and the presence of desired characters in choosing a different camera model. quantity of vision algorithms availa specific location. The OCR tool To solve current applications and able to process and analyze captured can then compare text with transfuture-proof a manufacturing enterimages is greater than ever before. mitted strings from industrial EthApplications engineers can use a

Strengthens Production Quality

tech tips

 Two tools available in advanced software sets that can prove useful for many applications are advanced pattern find and OCR tools.

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 The advanced pattern find tools provide a solution for variably positioned part location, inspection and identification challenges.

VISION & SENSORS | March 2011

 Future developments in machine vision hardware and software likely will be focused around simpler programming and a better communication package.

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ernet protocol sources and transmit decoded ASCII text strings over RS-232, TCP/IP Ethernet, and Ethernet/IP or Modbus TCP/IP industrial Ethernet protocols. With an advanced OCR tool, today’s smart cameras may reliably read difficult dot-matrix printing, a challenge often encountered with label inspection, bottle inspection and package inspection. Dot-matrix codes, while less expensive to print, also are less repeatable because of characterto-character variation. OCR tools are fast—reading text strings as quickly as 1 millisecond per character, requiring only 10 milliseconds for a normal 10-character lot/date code. This ability makes OCR suitable for many high-speed inspection applications.

UNIVERSAL SOFTWARE WITH SIMPLE SETUP

The latest vision systems allow up to four cameras to be connected to a single controller, enabling that controller to process and perform multiple inspections. Source: PPT Vision

Today, software offerings are available to make all inspection, guidance and identification programs universally operational on all of a manufacturer’s vision system and smart camera models. Since the identical software suite is used with all the manufacturers’ cameras, operators can transport any inspection program between the

pinpoint pattern find tool, OCR tool and many additional tools to handle any measurement, surface flaw, guidance, logic or communication task. One of the first questions an engineer should ask when deploying a vision system or vision sensor is, “Who will be maintaining this system?”

Software offerings are available to make all inspection, guidance and identification programs universally operational on all of a manufacturer’s vision system and smart camera models. differing models. This arrangement saves time and resources because operators trained on the software suite can use it for all applications in the plant. Additionally, intuitive programming features lessen the amount of training required to set up and deploy machine vision applications. Engineers can design custom inspections—utilizing a

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If the answer is people within a company’s enterprise, then it may be best to consider an easy-to-use graphical programming. A vision program manager (VPM) may feature an intuitive library of icons and straightforward drag-and-drop tree programming, with no knowledge of programming languages or syntax required. An offline emulator allows operators to create and test inspec-

tion programs on any PC without a camera connected. Most machine vision operators require a human-machine interface at or near the inspection point on the assembly line. However, a control program manager (CPM), a PC-based rapid application development environment, also can be used for these types of applications. It displays visual images from the cameras and helps make plant operators and management more productive and efficient. CPMs may come with more than 60 fully configurable controls, allowing operators to create custom, professional control panels with multiple image displays, data charts, real-time inspection results with passwordprotected panels, frames and tabs. Drag-and-drop linking provides easy CPM setup from a VPM program and snap-to-grid allows for fast and easy graphical alignment.

THE FUTURE OF INDUSTRIAL MACHINE VISION SOFTWARE New, advanced tools, along with universal software designed for sim-

March 2011 | VISION & SENSORS

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VISION & SENSORS

ple setup and operation, allows for a broad range of customized machine vision solutions today, along with future-proof development as processor speed, communications and operating systems are continually updated. This saves significant

S O F T WA R E

expense and engineering time, while also saving significant investments in new software and hardware. Future developments in machine vision hardware and software likely will be focused around these same goals: simpler pro-

gramming and a better communication package designed to deliver inspection information so it strengthens production quality and throughput. For instance, the latest vision systems allow up to four cameras to be connected to a single controller, enabling that controller to process and perform multiple inspections. The newest systems allow the camera inspection points to be triggered asynchronously, with cameras placed far apart from each other, allowing detailed inspections to be performed on one or multiple independent vision processes in multiple segments of a production line. A variety of parameters can be inspected with a single system, including dimensions, implied coplanarity—two-dimensional (2-D) cameras with structured lighting— positioning and identification markings—both human readable text labels and barcodes. These systems also can simplify the inspection process when differentiating parts, locating defects and detecting flaws on four sides of a part. This arrangement saves significant expense and time because operators can replace up to four smart cameras with a single vision system. Programming can be created for four inspections with a single interface, and an advanced software system can be used to make programming intuitive and fast. In addition, since the software is universal, the inspection and guidance program is operational on other camera platforms if a change is made in the future to better suit the application. V&S Steve Maves is applications engineer manager at PPT Vision (Bloomington, MN). For more information, call (952) 996-9500, e-mail info@ pptvision.com or visit www.pptvision.com. For more information on software, visit www. visionsensorsmag.com to read the following: • “Five Reasons to Invest in Vision Software” • ”Machine Vision Inspection Software” • “Seize Software Opportunities”

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SENSORS

Going the Distance

The demand for these types of applications in manufacturing has resulted in the introduction of many distance measurement sensors, SHORT-RANGE DISTANCE MEASUREMENT SENSORS OFFER HIGH primarily using optical principles. ACCURACY WITHOUT CONTACT, REQUIRE NO CALIBRATION AND These sensors produce outputs, PROVIDE SIMPLE PROGRAMMING. By Rick Bondy which are most often analog values that are correlated to the distance to the target. Depending on the level of performance required for each application, operators can choose from a variety of distances from submicron to mile. Many distance measurement sensors use Class I and Class II lasers as their light source as opposed to older sources, such as infrared Shown here is inspec(IR) and light-emitting diode tion of machining tol(LED). The long life expectanerances on an engine cy and small spot size of these block using an OD sensor. Source: Sick lasers have greatly improved over the years. Low average wattage makes these lasers safe in all factory automation and quality inspection processes. The distance to the targets can be identified as short-range (