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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MACHINE VISION 101

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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 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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VISION & SENSORS | March 2011

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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 (<700 millimeters); medium-range (700 millimeters to 30 millimeters); and longrange (30 meters to 120 meters). Short-range distance measurement sensors, often referred to as optical displacement sensors, are typically used in quality control processes to measure dimensions, positions and Typically, photoelectric applications are for simple shapes such as width, height, thickcurvature, diameter, deformapresence detection to confirm whether a target is pres- ness, tion, position and vibration.

in Manufacturing

ent. Many applications in today’s market now require confirmation that not only is the target present, but the distance of the target in relationship to the sensor must be determined as well. An example would be if the target is a metal sealing ring that must be inserted into an assembly in a specific posi-

tech tips  Short-range distance sensors are an ideal alternate in many applications to linear variable distance transducers probes (LVDT) and are cost competitive when motion of the probes is required.

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tion rather than simply to confirm the ring is present; a distance measurement sensor would give an analog value relevant to the actual opposition.

 High accuracy, noncontact measurement sensors are utilized in automotive, packaging, machining, robotics, tooling and generally all manufacturing areas.

VISION & SENSORS | March 2011

SHORT-RANGE BASICS Short-range distance sensors are an ideal alternate in many applications to linear variable distance transducers probes (LVDT) and are cost competitive when motion of the probes is required. LVDT probes require contact with the target material, which could

 A general principle to follow is that the closer the sensor is mounted to the target material, the higher the performance.

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damage the probes and also require regular calibration of the probes. While many quality managers believe that probes are more accurate than noncontact sensors, this has been proven incorrect with the advent of new receiver technologies. Optical displacement sensors are available in two styles of operation. The first is standalone where the sensors are self-contained in a single housing and allow individual measurement capabilities. Sensor systems are the second style and are designed so that individual sensors interface with a common controller. This controller allows more functionality in the selection of various filters, output functions and easy programming compared to interfacing with a programmable logic controller (PLC) but at a much lower cost. Some controllers have the capacity to interface with up to three sensors to obtain calculated formulas between the sensors or receive individual measurements values from each sensor.

APPLICATIONS

basic distance to target requirement. A general principle to follow is that the closer the sensor is mounted to the target material, the higher the performance. The ideal solution also will need to consider three sensor specifications that are unique to distance measurement:

An OD sensor confirms accurate positioning of target in a

robotic application. Source: Sick Quality inspections primarily focus on the short-range dis1. Resolution. This is the unit of meatance measurement products that surement that the sensor is capable deliver the best resolution, repeatof measuring. For example, with ability and accuracy. In applicaa simple ruler for linear measuretions where parts are measured to ment, the resolution is 1-millimeter tolerances in micron and submicron or ¹/16-inch. The resolution goes levels, quality inspectors understand from 1-millimeter, 2-millimeter, 3that conditions must be conclusive to millimeter and more. support these high levels. Therefore, If the sensor considered has fixturing of parts/targets and envia specified resolution of 10 milronments must support the process limeters, then the next unit of for accuracy. Inspectors should not measurement in the scale would find high accuracy measurement senbe 20 millimeters, 30 millimeters sors at the bottom of the punch press and up. In the shorter sensing disor in areas of heavy coolant/cutting tances, resolutions of 0.02 micron oil presence. are achievable. 2. Repeatability. This is defined as DEFINITIONS the deviation of several measureIn selecting the best distance meaments performed under the same surement sensor for an applicaconditions. If the sensor measures tion, consideration must be given and sends an analog value every to certain issues in addition to the

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millisecond, these values should be very similar and consistent if the repeatability is good. This specification is the most critical of these three variables. In the shorter sensing ranges, repeatability of 0.06 micron can be utilized. 3. Accuracy. This can be explained as the maximum expected measuring error between the determined and the actual distance. Differences in accuracy can be stated in either millimeters/microns or in percentage of full scale measurement range. If the accuracy specified is ±1% of full scale and the sensor has a full scale of 20 millimeters, then the accuracy would be ±0.02 millimeter. Some manufacturers do not specify accuracy but refer to this as linearity. This is defined as the maximum deviation between the output signal and an ideal straight characteristic. Offset and gradient errors can still exist and must be considered. With shorter ranges, accuracy of ±1.6 microns can be maintained. In addition to the three characteristics defined, consideration in the application must be given to response time — time between the actual measuring tasks vs. output changes. If the application is to measure the machining tolerances of a metal surface, the response time would not be critical as opposed to measuring the thickness of postal mail travelling at 6 meters/second. Other considerations are type of interface outputs. Generally, simple switching outputs with high and low set points would offer uncomplicated logic to indicate pass and fail in the process. Analog outputs in either 4 to 20mA current or 0 to 10VDC voltage signals allow monitoring and easy adjustments to process tolerances and variables. The best solution can be determined by the personnel who oversee quality.

March 2011 | VISION & SENSORS

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VISION & SENSORS

SENSORS

In an automotive application, a steel ring is inserted into transmission part. The ring must be assembled in a specific position (and not upside down) to ensure quality assembly. The OD sensor measures the part position by using the switching output for go/no go indication. Source: Sick

TECHNOLOGIES By understanding the technology used in the sensor, the operator can easily apply the product in the most beneficial manner. Two primary optical technologies are used in distance measurement sensors. There are positive attributes with each method and other unique characteristics of which operators must be aware: 1. Triangulation. This takes place when a laser light spot is projected onto the target. The reflection from the light is then mapped onto a light-sensitive receiver element. Based on the position of the mapped light spot and the known geometry of the sensor optics, the distance is determined. This method requires the light spot’s return to the receiver to be angled and cleared of any obstructions. When an application requires the measurement of the depth of a narrow hole, caution must be observed since the entry path is often too narrow for the returning light to clear the hole at an angle. In other words,

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the light is allowed to enter the hole but cannot exit it without striking the side of the hole. Sensors that utilize triangulation offer high accuracy performance at short distances. Even though all optical displacement sensors use triangulation, the receiver technology varies depending on the manufacturer. Some vendors will use position sensing detector (PSD) receivers which is a simple photo diode similar to baseline photoelectric sensors. This older receiving method can output different measurement values dependant on the color/remission of the target, such as dark vs. light, and a colored target equals different values. Some vendors use chargecoupled device (CCD) receivers, which are commonly used in digital cameras. Both receiver styles are particularly prone to being blinded by shiny targets when the returning light exceeds thresholds in the receiver. This effect is called

VISION & SENSORS | March 2011

blooming and can be experienced in digital photography when the receivers are blinded by bright light. As a result, many manufacturers prefer complementary metal-oxide semiconductor (CMOS). CMOS receivers feature natural anti-blooming characteristics and measure dark remission and light remission targets with high accuracy. 2. Time-of-flight. In general terms, time-of-flight measures the time it takes for the light to return to the receiver rather than the amount of light as in baseline photoelectric sensors. There are several benefits to this method, which include severe angles to the target and very long distance measurement capabilities. Caution must be applied to the remission color of the targets though and most manufacturers will specify sensing ranges for various color remission levels.

BENEFITS Regardless of the market segment, the importance of producing quality products is not undervalued in today’s competitive markets. High accuracy, noncontact measurement sensors are utilized in automotive, packaging, machining, robotics, tooling and generally all manufacturing areas. With a wide variety of measurement sensing ranges, interface styles and easy-to-set up programming, these distance measurement sensors can help ensure quality inspections and processes. V&S Rick Bondy is optical displacement sensors product manager at Sick (Minneapolis, MN). For more information, call (800) 325-7425, e-mail [email protected] or visit www.sick.com.

VISION & SENSORS ONLINE For more information on sensors, visit www. visionsensorsmag.com to read the following: • “Choosing the Appropriate Sensor Technology” • “Industrial Vision Sensors vs. Standard Photoelectric Sensors” • “The Photoelectric Solution”

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VISION & SENSORS

LENSES

Flexible

Imaging Lens Designs

CONSIDERATIONS

The biggest downside to trying to incorporate significant forethought and intelligent design up front is that it can lead to lengthy and complex design process and CLEVER FEATURES AND PROPRIETARY TECHNIQUES CAN TRANSFORM may result in more variables, A SINGLE-USE DESIGN INTO A MULTIPURPOSE SOLUTION. which can go wrong in the initial By Nicholas D. James prototyping phase. But the final result tells the story: production lenses that are advanced pieces of technology, superior quality and more suited to the ever changing needs of the world from machine vision integrators and systems OEMs to corporate and college labs. For instance, when designing a lens, it is critical to first define its overall scope. Should the new high-resolution fixed focal length lens design maximize a ⅔-inch, 5-megapixel sensor This high-resolution 5-megapixel fixed focal with 3.45 micron pixels? length lens comes When the answer is yes, in two focal lengths and features multiple this quickly leads to addiversions to optimize tional questions, such as at for different working what working distance and distance ranges. Source: Edmund Optics magnification is needed, and is performance at the edge of the field equally as critical as performance at the center? Many of the commercially availThe needs of the imaging world are continuously evolving, able 5-megapixel lenses in prorequiring lenses to be lower cost, higher resolution and duction have focused on the first more versatile than ever. The increasing demands neces- question without considering the sitate lens manufacturers and designers to develop more importance of the second set of questions. Many of the companies adaptable, more efficient and more economical lenses. have 5-megapixel lenses that will maximize the sensor, but only in the center of the image, and only over a and proprietary techniques can VERSATILITY very small working distance range transform a single-use design into a Before a lens is produced or that cannot be changed, greatly multipurpose solution. Such adaptdesigned, the versatility and manureducing the usability and predictability increases volume producfacturability of the lens must be ability of the lens. tion, lowers costs for end-users and considered and incorporated into However, lenses with true OEMs, and makes projects more the design process. Clever features 5-megapixel performance across economically viable when considerthe entire image field and over ing long-term forecasts.

tech tips

 By substituting in subtly different front or rear optical elements into multi-element designs, a manufacturer can shift the optimized region for this type of lens.  Focusablity is the most straightforward benefit to achieve and is accomplished simply by putting an extended amount of threading onto the lens.

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 An iris, although not cost feasible in most micro video lenses, allows the operator to vary the f-stop of the lens being used, resulting in increased control over the balance between resolution, light collection and depth of field.

March 2011 | VISION & SENSORS

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VISION & SENSORS

LENSES

A compact micro video lens must forego many of the features in a traditional fixed focal length lens, such as a focus ring, an adjustable iris and filter threading. Source: Edmund Optics

a broad range of working distance options are available that offer performance advantages to customers. These advantages include the ability to resolve highresolution with strong contrast at any point of the image and knowing that this can be predictably achieved anywhere from very close up, out to infinity. This can be achieved using a clever design method, which, while adding a small amount of manufacturing complexity, increases the useable range of high-resolution lenses. By substituting in subtly different front or rear optical elements into these multi-element designs, a manufacturer can shift the optimized region for this type of lens. Instead of buying a lens that has been optimized at one working distance and provides inferior performance everywhere else, this design technique yields lenses with multiple optimized conjugates (working distance ranges) versions for the manufacturer to choose from. Typically, two or three versions will cover the full range of options, from 200 millimeters to infinity, allowing one to select the most suitable lens for the current application.

ADAPTABILITY While inventive approaches in the optical design can lead to great benefits, sometimes all that is necessary to increase the functionality of a lens design is to modify

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These high performance imaging lenses offer high-resolution and are designed specifically for line scan and large area scan cameras. Source: Edmund Optics

the metal that surrounds the lenses. For instance, a compact micro video lens must forego many of the features in a traditional fixed focal length lens such as a focus ring, an adjustable iris and filter threading. However, this does not mean that many of the same benefits cannot be achieved with just a bit of effort on the part of the lens manufacturer. Focusablity is the most straightforward to achieve and is accomplished simply by putting an extended amount of threading onto the lens. This allows the operator to screw the lens in and out to achieve best focus. Locking also can still be achieved with locking nuts designed for use with this type of lens. An iris, although not cost feasible in most micro video lenses, allows the operator to vary the f-stop of the lens being used, resulting in increased control over the balance between resolution, light collection and depth of field. To mimic this feature, the aperture at the stop of the lens can be mechanically designed to have different sizes substituted on the production floor. This allows an 8-millimeter lens designed to have a minimum aperture of f/2.5 to quickly have other versions available, such as f/4, f/8 or whichever is needed for an application, without a new design process. Such adaptability provides options and significant value to custom-

VISION & SENSORS | March 2011

ers. A good lens manufacturer or system integrator can work directly with the customer to determine the specific f-stop requirements of their system, and can quickly deliver an off-the-shelf lens or a slightly modified custom lens, tailor-made to the customer’s needs.

METHODS The most complex feat is trying to gain some of the benefits of filter threading, particularly the ability to have an IR-cut filter. Within a micro video lens this is predominantly achieved in one of two methods. The first method involves leaving all of the metal components the same and coating one of the lens surfaces with an IR-cut coating. The downside to this route is that filter coatings can be highly angledependent, and putting one on the surface of a lens, particularly one that still requires high visible transmission, can be costly and problematic, in addition to requiring a new production run of at least the newly coated lens. The second option is to insert a thin and flat IR-cut filter into the lens path allowing for higher levels of transmission and light control. However, this cannot always be accommodated with the existing metal design and may require a new housing to be ordered. Both methods are used by lens fabricators, and show that a simple lens design does not have to decrease flexibility.

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The last example of a clever optical design technique is the most complex, but also the most rewarding to customers. The technique requires a dynamic, robust optical design coupled with mechanical modifications resulting in a design capable of adapting to many magnifications while maintaining highresolution and fast f-stops. A typical design solution for this fixed magnification lens exists which allows for one set of optical elements that, with a small number of changes, can have full performance functionality from 0.33X to 3X. With only a minimal number of internal mechanical part changes, the spacing can be altered, providing the 0.33X to 1X range, and by allowing the entire assembly to be flipped or rotated 180 degrees, the lens achieves the 1X to 3X range. This allows rapid customization of magnification for any standard magnifications offered. For example, if the standard part has a 2X option, it can be customized into a 2.4X part with just a few internal part changes at the factory during assembly.

cation, budget and time to market are all beneficiaries. V&S Nicholas D. James is product line manager, imaging, at Edmund Optics (Barrington, NJ). For more information, call (800) 363-1992, e-mail njames@ edmundoptics.com or visit www.edmundoptics.com.

VISION & SENSORS ONLINE For more information on lenses, visit www. visionsensorsmag.com to read the following: • ”Eliminate Image Distortion” • ”Integrated Vision” • ”Sensor Standards Require Superior Optics”

Dual GigE Cameras at 240 MB/s Speed and Resolution without Compromise

ART AND SCIENCE Lens design is as much an art as it is a science; it requires a vast technical know-how and also needs creative imagination and the courage to try something unconventional. Designing lenses today is more difficult than ever, thanks to increasing camera sensor resolutions and decreasing pixel sizes, coupled with the pressure to lower costs and to fully satisfy customers’ needs and expectations. Through clever engineering, adaptable manufacturing and significant forethought upfront, however, superior lenses can be produced. Whether the end result is an off-the-shelf solution that fully meets the customer’s needs, or a lens that is quickly and costeffectively modified for optimum performance, the customer’s appli-

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March 2011 | VISION & SENSORS

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CASE STUDY

Scanning for Safety AUTOMATED INSPECTION SYSTEM EMPLOYS LINE SCAN CAMERAS TO ENSURE RELIABLE BRAKE DISC QUALITY.

Ibea’s automated assembly process benefits from the detection capabilities of Teledyne Dalsa’s line scan cameras. Source: Teledyne Dalsa

Flawless brake operation is so essential to the safety of a vehicle that all brake systems have passed safety testing before a driver ever gets behind the wheel. But how much better would you, as a driver, feel knowing that the raw brake discs of your motorcycle or minivan were inspected for any flaws even before brake assembly began? And, from a manufacturing perspective, what if such an inspection yielded better quality while boosting profitability? A custom-designed machine vision inspection system from Ibea GmbH (Hamburg, Germany) uses cameras from Teledyne Dalsa (Waterloo,

benefits

Ontario, Canada) to provide these benefits and more for automotive suppliers, manufacturers and customers alike.

PUTTING THE BRAKES ON FAULTY PARTS Manufacturers tend to rely on manual inspections to detect nonconformities on raw brake discs. Frequent shift changes and the sub-

 Images taken of the brake disc inspection system identify all defects using only one image acquisition and a dark field illumination technique.  Ibea’s automated brake disc inspection system provides reproducible, series-production quality that

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jective nature of these inspections lead to lower reliability and, subsequently, to increased manufacturing costs resulting from returns. As a result, Ibea, which has developed, produced and integrated industrial processing systems since 1991, recently introduced an automated system that integrates the inspection and handling of brake discs. By replacing manual inspection methods and integrating production line components and machinery, the automated Ibea system provides automotive industry manufacturers with a comprehensive overview of the entire brake manufacturing process, and with a documented and reproducible method of ensuring brake disc quality. The Ibea inspection system is built around a simple centering device for well-defined rotation of brake discs with diameters up to 50 centimeters and heights up to 15 centimeters. As each disc rolls along a conveyor, it is transported into the test cell via a front-end entry pulsing device and, upon triggering a sensor, stops at the centering device. The disc is pre-centered by three rollers, one of which is driven, for exact centering. The disc then rotates 360 degrees, during which time three Teledyne Dalsa Spyder2 line scan cameras take images of the upper, lower and cooling channel sides of each disc. “I like to use Teledyne Dalsa cameras because of the vast selection of cameras, good quality and reasonable prices,” says Akram El Jarad, project manager at Ibea. Ibea had worked with Teledyne Dalsa previously to design customized systems for the metal sheet, abrasive paper, ceramic and other industries.

dramatically reduces the quantity of faulty parts shipped, recouping a manufacturer’s investment within 1.5 years.  Using Ibea’s custom-designed program, disc parameters can be set, saved and started up by shop floor personnel.

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On the brake disc inspection system, the images taken are arranged in such a way that all defects can be found using only one image acquisition and a dark field illumination technique. Since 90% of brake disc defects occur during the casting process—only about 10% are surface or core flaws—and involve indentations, dark field illumination can reliably detect any cavities. Contrast imperfections are handled separately. Discs are inspected at a rate of approximately six to 10 per minute for diameter and height, imprint or symbols, blowholes, flash, filled ventilation channels, half fans, bubbles in the fan, cracks and deformities. Good parts proceed along the conveyor while faulty ones are diverted and ejected from the line for rework. Using Ibea’s custom-designed program, disc parameters can be set, saved and started up by shop floor personnel.

This handling and inspection procedure minimizes wear and tear on parts, makes expensive handling robots unnecessary and provides highly accurate images that also can be used for measurement purposes. Ibea introduced the brake disc inspection system to the market in 2009. This automated vision solution provides reproducible, seriesproduction quality that dramatically reduces the quantity of faulty parts shipped. According to El Jarad, the manufacturer’s investment can be recouped within 1.5 years. “The Teledyne Dalsa cameras that are the heart of this system provide a cost-effective, yet high-performance, solution,” he says.

More Precision Non-Contact Dimensional Testing Confocal sensors optoNCDT 2400 Miniature sensor design Extreme resolution

Teledyne Dalsa (519) 886-6000 www.dalsa.com

Tiny, constant measuring spot 7 μm Target independent even against mirror & glass Standard sensors ø 27 mm, also for one-sided thickness measurement Miniature sensors ø 4 mm, also for cavities and bores

Optical micrometer optoCONTROL Highest resolution Ranges 0.3 - 40 mm Resolution 0.1 μm Repeatability 1 μm Measuring rate up to 100 kHz Measurement of diameter, gap, edge, position & segment For all materials including glass and plastic

www.micro-epsilon.us MICRO-EPSILON Raleigh, NC 27617 / USA Phone +1/919 787 9707 Fax +1/919 787 9706 [email protected]

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VISION & SENSORS

PRODUCTS

4G SENSOR

SWIR CAMERA The SU640KTS is a large-format, indium gallium arsenide, high-resolution, short-wave infrared (SWIR) snapshot video camera. It operates in the SWIR region, from 0.9 microns to 1.7 microns, at 30 frames per second. The 640 by 512 pixel array camera with 25 µm pitch has built-in non-uniformity corrections, automatic gain control and adjustable automatic contrast enhancement. It has met Conformite Europeene and the U.S. Federal Communications Commission standards for radiated and conducted emissions, for immunity from such emissions and for electrostatic discharge resistance.

The Checker 4G vision sensor has Ethernet networking for remote setup and monitoring, PLC communication and the ability to save inspection images to an FTP server. It allows the operator to configure the sensor as a presence sensor or measurement sensor to inspect and error-proof the manufacturing process. The sensors also are able to detect and inspect more than 6,000 parts per minute in varying positions along the production line. Cognex Corp. (877) 264-6391 www.cognex.com

Sensors Unlimited • (609) 520-0610 • www.sensorsinc.com

EMBEDDED VISION SYSTEM

NANO CAMERAS The VC Nano camera series come in the form of single-board cameras or with a protective enclosure. They are based on a board that is populated on both sides and are 40 by 65 millimeters or 80 by 45 by 20 millimeters. Some models have a remote camera head measuring 22 by 22 by 19.5 millimeters. The cameras have IP68 enclosures, including lenses and lighting, for use in rugged industrial environments. Vision Components GmbH • (603) 598 2588 • www.vision-components.com

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The Impact M-Series Embedded Vision System has Power over Ethernet (PoE) support, using standard CAT 5 Ethernet cables. System cameras are powered from the embedded M40 processor, which eliminates the need for a separate computer for programming and processing and individual data and power cables. Cable wiring is limited. The PoE allows for increased system flexibility by allowing devices to be located at distances more than 100 meters from a power supply. PPT Vision (952) 996-9500 www.pptvision.com

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VISION & SENSORS | AD INDEX ADVERTISER

PAGE

PHONE

BC

(877) USA-1394

www.alliedvisiontec.com

Baumer Optronic GmbH

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(800) 937-9336

www.baumer.com

Cincinnati Automation Ltd.

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(859) 371-5070

www.cincinnatiautomation.com

Edmund Optics Inc.

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(856) 547-3488

www.edmundoptics.com

Epix

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(847) 465-1818

www.epixinc.com

Kowa Optimed Inc.

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(800) 966-5692

www.kowa-usa.com

Matrox Imaging

IFC

(800) 804-6243

www.matroximaging.com

Allied Vision Technologies

WEB ADDRESS

Micro-Epsilon

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www.micro-epsilon.com

Pepperl+Fuchs

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(330) 486-0001

www.sensing.net/autorack-i

Pixelink

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(613) 247-1211 x400

www.pixelink.com

Point Grey Research

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PPT Vision

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Teledyne Dalsa

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www.grasshopper2.com (952) 996-9500

www.pptvision.com www.teledynedalsa.com/boa/vs3

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

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Quality | HOW TO GUIDE

Table of Contents 2011 HOW TO GUIDE This How To Guide is a special advertising section designed to help you make decisions when purchasing quality equipment and products. Companies that are experts in their field present suggestions, ideas, tips and general practical information to help you do your job better.

Choose the Correct Target Technology for Your Laser Tracker ...................................................................................2HT

Automated Precision Inc. How to Properly Prepare Samples for XRF Alloy Analysis ........................................................................4HT

Bruker Elemental How to Quantify Shaft Lead Angle of Dynamic Sealing Surfaces .............................................................................6HT

Bruker Nano How to Develop and Document FDA-Compliant Inspection Processes .....................................................................8HT

Carl Zeiss How to Choose Calibration Software That Measures Up...................................................................................10HT

CyberMetrics Corp. How to Choose an In-House Calibration System for Your Handheld Gages and Tools ...............................................12HT

Gagemaker Inc. How to Conduct More Efficient Remote Visual Inspection..........................................................................14HT

GE Sensing & Inspection Buying a Previously Owned CMM ............................................16HT

Hexagon Metrology Inc. How to Ensure Effortless, Ongoing ISO 9001 Certification and Perpetual Audit Preparedness .................18HT

Intelex

QUALITY | How To Guide | March 2011

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How To Get the Most Out of Your Micro Hardness Tester ............................................................................20HT

Mitutoyo America Corp. How to Leverage Process Approach Auditing for ‘Bottom-Line’ Results...................................................................22HT

NSF International How to Verify Alloy Materials Using Handheld X-Ray Fluorescence (HH-XRF) ...................................................24HT

Olympus/Innov-X How to Use an Ultrasonic Thickness Gage ............................26HT

Olympus NDT How to Choose and Use Styli .....................................................28HT

Renishaw Looking for Noncontact Inspection? .......................................30HT

S-T Industries Inc. How to Close the Loop on the Digital Manufacturing Workflow............................................................32HT

Verisurf

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March 2011 | How To Guide | QUALITY

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Quality | HOW TO GUIDE

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Choose The Correct Target Technology For Your Laser Tracker urchasing a laser tracker is no small matter. Most advanced systems are a sizable capital investment. The full potential of a laser tracker can be realized in the targets that a user chooses for the application. Some basic questions need to be asked when selecting a target:

P

A robust, hollow SMR is constructed using a hollow aluminum optic coated with golden reflective surfaces. This construction endures harsh environments and treatment more readily, as well as lending itself to highly precise measurements.

• Are you measuring simple distance, or do you want to measure in multiple axes?

BEING ‘ACTIVE’

• What is the environment in which the target will be used?

In some applications, where the object to be measured is in motion, an “automated SMR” is needed. The “motorized SMR” solution should lock on to the laser tracker and positions itself so as not to lose the laser beam. The reflector faces the laser tracker, regardless of movement. With these attributes an operator has opened up the possibility of a new range of laser tracker applications that include measuring,

• Will the target be fixed or is mobility an issue? • What is the complexity of the part you want measure? MOST CHOSEN The most often used target is the spherically mounted reflector (SMR). Typically, these are configured in one of two ways—prismatic or hollow. Prismatic SMRs have a solid glass prism corner cube inside a machined steel sphere. This configuration provides the longest linear range of measurement.

• the compound actions of robots, • long rails, • moving vehicles, and • CMM and CNC positioning, In more advanced applications, such a motorized device helps deliver volumetric error compensation on multiaxis CNC machining centers. A SMART TARGET If a laser tracker needs to be used in large-scale measurement applications, the customary solution may to use three separate trackers. However, automation in a “smart” sensor—one that can determine position in the x, y and z axes, as well as pitch, yaw and roll—can save a user considerable time, expense and ensure great accuracy. A “smart” target gets its identification as such because it uses a motorized receiver that tracks the laser beam in real time, providing object pitch and yaw. It also uses roll detection technology to provide the object’s roll angle. HANDHELD PART PROBING A handheld probe and/or scanner combination uses a target similar to an SMR in a sensor head, but it also

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incorporates a probe to access hidden points and/or a scanner to do dynamic noncontact scanning. The more degrees of freedom that the sensor head possesses, the more easily it can be used in measurement applications such as: • tooling, fixtures and jigs • automotive body parts • mold and die cavities • surface contours • part inspection • compare-to-CAD • gap and flush measurement • in-process inspection Earlier probes, which rely on photogrammetry techniques are limited in distance and their orientation on a 2-D plane. More advanced solutions use a rotating sensor head instead of photogrammetry. In this technology, the advanced sensors located inside the target allow the system to be used over the full range of the laser tracker, thus maximizing that investment. In addition, the advanced solution technology permits a user to both scan and probe with a single target unit. Thus the user has an economical and flexible solution. A wireless version of these advanced targets provides even greater targeting versatility.

For more information regarding targeting and laser tracker solutions, contact: Automated Precision Inc. 15000 Johns Hopkins Dr. Rockville, MD 20850 PH: (800) 537-2720 www.apisensor.com [email protected]

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March 2011 | How To Guide | QUALIT Y

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How To Properly Prepare Samples for XRF Alloy Analysis A

lthough handheld X-ray Fluorescence (HH XRF) analyzers are a boon to alloy analysis, there may be quality control problems if they are not used with properly surfaced samples. It’s not always as simple as “point and shoot.” Technicians and their supervisors must be aware of possible quality issues with unsuitable sample surfaces. For a clean, flat, smooth metal sample surface which completely covers the measurement window; HH XRF can always provide an accurate alloy grade ID and chemical analyses worthy of laboratory instrumentation. The penetration depth of X-rays in steel is typically less than about 100 microns (μm), depending on the X-ray energy. These incoming X-rays and the characteristic X-rays emitted by each element may be absorbed by any intervening matter, such as paint, coatings, and corrosive layers. Such absorption or attenuation of the X-rays can seriously affect the analytical performance of the analyzer. The reduction in analytical integrity (i.e., precision and accuracy of analysis) will be especially severe for the lighter elements (i.e., lower than Ti in the Periodic Table) due to the very low energy of these X-rays. The user would be well advised to carry a portable grinder. Typical grinding disks use 80 or 120 grit aluminum oxide. A light grind for 5 to 10 seconds will usually be sufficient for the specific problem areas discussed below. 1. Paint: If possible, choose an unpainted portion of the sample. If not, perform a light grind to provide a clean spot for the analyzer. 2. Coatings: There are many types of coatings associated with metal samples, but oil is probably the most common. Wipe the sample to remove the bulk of the oil. If you are measuring light elements oil is a much greater problem, in this case if possible, use a bit of acetone to properly clean the surface. 3. Plating & Corrosion: A common plating is the zinc coating on steel to produce “galvanized” steel. The analyzer will detect a lot of zinc and some of the underlying iron and fail to match any alloy in the library. Fortunately, such surface conditions

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are generally evident from visual inspection and a light grind should quickly provide a sample surface adequate for alloy analysis. 4. Surface Roughness: A flat, smooth sample surface is optimal. If initial analyzer results are ambiguous (i.e., uncertain alloy grade ID), then use the grinder. Alloys of aluminum and magnesium, light metal alloys, are particularly susceptible to poor sample surface condition due to the scatter which will be caused by uneven surfaces.

Author: John I.H. Patterson, Ph.D. Director of Marketing Bruker Elemental 415 N. Quay St. Kennewick, WA 99336 USA (800) 466-5323 www.bruker.com/hhxrf [email protected]

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How To Quantify Shaft Lead Angle of Dynamic Sealing Surfaces F

ailures attributed to leaking seals cost the transportation and power industry millions of dollars a year in warranty costs, recalls and fines. Advances in seal and shaft materials and design have extended end product lifetimes and reliability. As a shaft rotates, fine machined grooves wick lubricant through the shaft-seal interface. The amount of lead on a shaft’s surface contributes to the amount and effectiveness of the lubricant at the sealing interfaces. Since the measurement of a shaft’s lead angle is so important to predicting the performance of the dynamic seal, tighter tolerances have been outlined in the industry specifications ISO 6194 and RMA-OS-1-1 rev. 2004. However, traditional measurement techniques have

had difficulty in reliably verifying these specified parameters.

QUALIFICATION VERSUS QUANTIFICATION Historically, shaft and seal manufacturers qualify their parts using a defined combination of stylus and string measurement methods, which depend heavily on part alignment, mounting, and operator experience. The contact nature of these techniques makes them susceptible to imperfections in shaft surfaces, leading to inconsistent results. The string method in particular has proven to be qualitative rather than quantitative, particularly from operator to operator, and lacks sensitivity to detect micro lead and lead angles near 0 degrees. Bruker has developed the NPFLEX-LA™ 3D Surface Metrology System, the first quantifiable surface measurement instrument specifically designed for lead angle measurement. Leveraging the intrinsic benefits of non-contact, interferometry-based optical profiling technology, the NPFLEX-LA predictably and quantifiably measures both shaft lead angle and surface texture of sealing surfaces in a single integrated solution. The system has been designed to be independent of surface finish and part mounting and setup inconsistencies, such as warp, level and concentricity. A reliably quantifiable technique enables manufacturers to make better decisions on machining processes.

THE BENEFIT OF THREE-DIMENSIONAL PARAMETERS Though the NPFLEX-LA can calculate the two-dimensional

The Bruker NPFLEX-LA 3D Surface Metrology System for Lead Angle.

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The NPFLEX-LA enables both 2D and 3D analyses of surface texture.

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calculations are subtracted from each other at every measurement point, to eliminate any bias due to part alignment, wobble, or out-of-roundness errors. The result is a lead angle measurement independent of part alignment, and unaffected by surface imperfections. In addition, roughness is calculated at each location, and the global roughness of the part is simultaneously reported.

COMPREHENSIVE RESULTS You can refine your data by simply setting pass/fail criteria to identify and/or eliminate scratches, defects, or contamination. These identified defects or anomalies are logged for future review, but are removed from the global lead angle calculation to maintain an accurate characterization of the part’s true lead. The NPFLEX-LA utilizes non-contact optical profiling to measure lead angle and surface roughness simultaneously.

parameters (Ra, Rz, and Rpm) generally employed throughout the precision machining community, it is inherently a 3D measurement instrument that calculates the equivalent three-dimensional (3D) surface parameters (Sa, Sz, and Spm). Such calculations are highly stable over the entire shaft as they encompass a large area, and are also insensitive to alignment, as the full 3D images are used in the calculation. Both lateral X and Y directions are measured simultaneous by scanning in the vertical direction. The result is a fast 3D analysis of the entire surface area.

SIMPLE STEPS TO RELIABLE MEASUREMENTS Operating the NPFLEX-LA is easy. An operator loads a shaft in a standard three jaw chuck, centers the shaft in the field of view of the microscope, and focuses on the shaft. Once mounting and focusing are complete, which takes less than 2 minutes, the user selects a pre-loaded, part-specific recipe and clicks the start button to begin the measurement routine. From here the system does all the work, scanning the surface at multiple locations. At each location the system calculates the best fit true cylinder to the surface and angle of that cylinder with respect to the system camera. The system also simultaneously conducts a Fourier transform of the data to determine an angular power spectral density of the angle of the machining marks on the shaft, with reference to the same system camera. These two

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Combining both the measurement of surface roughness with that of lead angle on a single platform, helps to improve product yield while facilitating ease-of-use and overall throughput. In this fashion the NPFLEX-LA delivers on the promise of a comprehensive, quantifiable, gage-capable lead angle surface metrology solution. Employing this technology will enable the transportation and related industries to better control and reduce fluid leakage of rotary dynamic seals.

For more information contact Bruker Nano Surfaces Business at +1.520.741.1044/800.366.9956 ext. 3, [email protected], www.bruker-axs.com

Comprehensive report shows pass/fail and critical performance results.

March 2011 | How To Guide | QUALIT Y

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How to Develop and Document FDA-Compliant Inspection Processes

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ue to the legal regulations and concerns for patient safety, strict monitoring of quality criteria is a necessity to the medical technology industry. The use of coordinate measuring machines (CMMs) in monitoring the manufacturing processes requires special considerations for medical device companies. According to the Code of Federal Regulations Title 21, Part 820.70 and Part 820.72, it must be ensured that all inspection, measuring and testing equipment is suitable for its intended purpose and produces valid results. Each manufacturer must therefore define and maintain processes to ensure the equipment is routinely inspected and serviced. Validation activities and results must be documented. MEETING GXP QUALITY GUIDELINES The principle determination of a CMM’s suitability can be ascertained based on appropriate validation documentation. At the very least, such documentation should contain internal approval documentation, quality management certifi cates, e.g. according to DIN EN ISO 9001, 14001 and 17025, calibration certifi cates, process documentation, notes on setup and use and declarations of conformity. Procedures for determining measuring uncertainty, inspection capability and measurement system analysis (using GR&R testing) can be used for taskspecifi c inspection.

Figure A

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QUALIT Y | How To Guide | March 2011

CMMs used in the medical device industry must be subject to regular calibration and typically annual maintenance. Some CMM manufactures have the capability to provide maintenance schedules based upon activity and device load. At Carl Zeiss, we use a software tool called Master Control Center (MCC). In this example, we use predictive tools such as Probe Collision data (Fig. A) to help determine needed service intervals (Fig. B). The FDA has signifi cantly changed the validation procedures required over the past years. Particular focus has been placed on the product and process knowledge; which are both crucial for ensuring high product quality and the associated high level of patient safety. Up until now, the fi xed development model (V model) was considered the standard for developing computer-assisted systems for the regulated industry. Today, it is only one of numerous models in the Good Automated Manufacturing Process (GAMP 5). All lifecycle models that allow quality to be developed into the system (quality by design) are now accepted. Consequently, agile software development models are allowed. Here, agile means that it is not necessary to first compile and sign complete requirement specifi cations

Figure B

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before the engineering specifi cations and the subsequent draft specifi cation are prepared. Requirement specifi cations can first be prepared in a rudimentary manner and later revised. During this time, the development of the system can already be started. GAMP 5 even recommends keeping documents in the draft stage, in other words, easily editable for a long time.

For more information please contact Chris Bomgaars, Strategic Account Manager – Medical, Carl Zeiss Industrial Metrology, LLC at [email protected].

AUTOMATICALLY SAVING THE INSPECTION RESULTS ELECTRONICALLY The most detailed regulations for the measuring process affect how the measured results, or measurement records, are handled. Since measurement records must essentially be electronically processed in an automatic test environment, the entire process is largely subject to the electronic document regulations according to 21 CFR Part 11. Here, Part 11 takes into account that the risk of manipulation, misinterpretation and untraceable changes is higher with electronic records than with conventional paper records, or is more diffi cult to detect. As a result, additional measures are required. At Carl Zeiss, we use MCC to track measuring part programs (Fig. C). The ability to electronically recall the current published version as well as previous and blocked versions meets the strict FDA standards for documentation. Medical device organizations must take control of their quality process with appropriate technology solutions. FDA–compliant software allows for risk reduction, greater complexity in the manufacturing process, and expanded innovation in the medical device industry.

The Carl Zeiss O-INSPECT optical-contact scanning CMM, used in the medical technology industry, is one of many devices that can be connected to monitoring software.

Figure C

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March 2011 | How To Guide | QUALIT Y

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How To Choose Calibration Software That Measures Up W

hen evaluating calibration management software, it’s important to be well-versed with your company’s internal and external requirements and processes, such as ISO/TS Quality Standards, FDA regulations, 21 CFR Part 11, as well as specific industry requirements and your customers’ requirements. To help you choose the right calibration management software solution, start by answering these basic questions: 1. What benefits and features do you need the solution to provide in addition to the requirements demanded by customers and/or industry standards? 2. Does the software need to integrate with existing company software systems or meet other requirements set by your IT department? 3. Does the solution provide options for live product support and training for a variety of user types and skill sets such as managers, engineers and technicians? 4. Will the solution allow for data import from your current system? A mid- to high-range software package will generally provide a solution focused on continuous adherence to common industry standards as well as scalability, deep feature sets and reliable product support, training and services. Some low-end packages may provide standards compliance, but these vendors usually do not have the resources to keep up with new technologies or evolving standards. Generally, a low-end package provides a quick fix; it is not a worthwhile investment for a company seeking a long-term or large-scale deployment of a calibration management solution. Look for an established software provider that has a long-standing industry reputation and offers a calibration software solution as a primary product offering. This type of provider is typically selling solutions, not just software packages. Being genuinely interested in a good fit and a long-term relationship, a solutions-minded software provider will be knowledgeable about your industry, will be interested in your success with the product and will offer continued support and training, ensuring successful implementation and utilization of their calibration management software.

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Author: Devin Brent Ellis, Director of Client Solutions CyberMetrics Corporation • www.cybermetrics.com

On the Go with GAGEtrak

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The World’s #1 Calibration Management Software Solution is now portable! GAGEtrak’s new Portable Calibration Solution (PCS) lets you export gage calibration data from your GAGEtrak software to a Netbook or laptop to perform calibrations in the field. Do You Outsource Your Calibrations? Don’t waste time re-entering data from your calibration certificates. Export your gage and calibration requirements to SD or USB Flash memory to send out with your gages. Your service provider uses the portable calibration module to update your calibration data which easily synchronizes with your GAGEtrak database, saving time and money.

PCS includes the portable calibration software module, your choice of portable printer and a Netbook.

Order the Portable Calibration Solution today and you’ll be going places!

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How to Handle Rejection

Cover Your Assets

Introducing SUPPLIERtrak® Supplier Quality Assurance Software

Introducing FaciliWorks® Enterprise Asset Management Software

Dealing with rejections wastes time and resources. Since it’s your job to protect your company and your customers from poor quality, you need to use suppliers that consistently deliver your materials on time and in spec. How do you track and document which suppliers deserve your business and which don’t? SUPPLIERtrak Supplier Quality Assurance Software is the answer. • Maintain a complete database of suppliers, parts and materials, eliminating the cost and errors associated with manual tracking. • Quantitatively measure supplier quality, allowing you to identify your best and worst suppliers. • Maintain costs of rejections, reworks and sorting. • Generate rejection notices and Accept and Reject tags. • Comply with ISO 9001:2000 requirements.

Use SUPPLIERtrak to monitor and rate your suppliers, so you can weed out the bad ones and stop wasting time with rejection.

by CyberMetrics

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How to

Whether your business has a single location or multiple facilities worldwide, FaciliWorks Asset Management Software will help you reduce maintenance costs, improve productivity and ensure greater asset uptime. • Manage assets, maintenance schedules, calibrations, personnel, tools, procedures, parts, budgets, suppliers and purchasing. • See your operations and asset status in real-time with Dashboard Analytics. • Easily submit, queue and manage work orders and service requests. • Customize the comprehensive set of reports. • Implement standards and compliance. Available in desktop, web-based and SaaS versions, FaciliWorks is easy to use, affordably priced and designed to grow with your organization. Over 12,000 facilities worldwide rely on our software solutions to maximize productivity, reduce costs and manage their assets.

Contact us today for a web demonstration and we’ll show you how FaciliWorks can work for you.

by CyberMetrics

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How to Choose an In-House Calibration System for Your Handheld Gages and Tools By Gagemaker, LP

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oday, calibration systems should offer more than just calibration. As systems are customizable, they can be as simple or as complicated as you need. Generally, companies have various gages and tools, from handhelds to permanent fixtures, which all need calibrating, setting, and zeroing. Historically, calibration has been viewed as a financial headache and a logistics nightmare. The expense of tracking, scheduling, shipping, instrument downtime, and the actual calibration service really adds up. Currently, companies who implement in-house calibration find that the systems pay for themselves in short order. For in-house calibration and gage setting, you want accurate, repeatable, reproducible results from a versatile, cost effective, easy-to-use system. Finding your perfect system can be achieved in 4 easy phases.

If many of your gages need less accuracy or just setting, then consider a basic shop floor system. However, accuracy is not the only requirement. Don’t overlook another significant cost saver- versatility. A versatile system should operate as a gage setting master, which avoids the purchase and storing of expensive standard sets. Not to mention, a linear measurement function is proven to be indispensable. PHASE 3: CONSIDER YOUR WORK ENVIRONMENT AND AVAILABLE SPACE If you need a shop floor machine, it should be durable enough to withstand the environmental rigors and increased usage found in a shop. Higher accuracy machines require a more controlled environment, e.g. temperature control, air quality, trained operators, and well defined procedures. No matter what type of environment, equipment size is a consideration. Do you have room for a machine with a large footprint? Or does a table-top or mountable machine fit better?

PHASE 1: INVENTORY YOUR INSTRUMENTS List your instruments to be calibrated, their calibration accuracy requirements, as well as what gages need setting. Once inventory is taken, consider three major points when choosing your equipment: accuracy, versatility, and environment. Of those, determining your desired level of accuracy is the key. Accuracy determines the work environment, operator skill, equipment size, and price. PHASE 2: REVIEW YOUR CALIBRATION AND SETTING REQUIREMENTS Some instruments need less accurate calibration than others. Calipers and micrometers often need a machine with less accuracy than do ring and plug gages (e.g. 0.001” vs. 0.0005”).

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PHASE 4: DETERMINE YOUR BUDGET AND SHOP YOUR OPTIONS Once your evaluation is complete, investigate all available options. Typically, companies with various gages balance their calibration program between in-house, manufacturer, and third party services. GAGEMAKER’S MIC TRAC Establishing in-house calibration grants greater control over the calibration process while saving time and money. The Gagemaker In-House MIC TRAC 4000 Series Precision Gage Calibration System enables you to inspect parts, calibrate and track a wide variety of gage styles, including ring and plugs. This innovative high precision metrology system with 1.00” travel guarantees extremely high accuracies to ±.00002 and a resolution of .00001” (traceable to the NIST). This system also enables you to track and maintain gage history and produce calibration certificates.

calibrate hand held gages, and preset indicator style gages. The Gagemaker Shop Floor MIC TRAC 3000 Series Gage Setting and Part Measurement System sets or zeros most gages with the standard resolution of .00005”, accuracies ranging from ±.0001” to ±.0004” (traceable to the NIST) and the digital read out is CE approved. The cost effective Force-Lok feature improves repeatability and reproducibility, along with being well suited for a variety of environments including the shop floor. For more information, contact Gagemaker today, www.gagemaker.com, [email protected], or 713-472-7360.

Employing a versatile bench mounted length measuring system allows you to measure parts,

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March 2011 | How To Guide | QUALIT Y 13HT

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How to Conduct More Efficient Remote Visual Inspection By Ed Hubben, Senior Product Manager- GE emote Visual Inspection (RVI) is a long-established inspection and non-destructive testing technique in multiple industries. RVI is an evolving sector within non-destructive testing, and its key for organizations to stay up to date on the latest technologies and techniques in order to conduct the most accurate and efficient remote visual inspection. Below are key components to conducting more efficient RVI.

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USE AN INDUSTRIAL-QUALITY VIDEO BORESCOPE Industrial-quality equipment is designed to be rugged, durable, and deliver high quality images. Features include higher light output, environmental sealing, and drop specifications. The first step in any remote visual inspection is to obtain a bright, clear image of the region of interest. Defect detection and interpretation depends on image quality, which in turn depends on industrial-quality equipment. MAKING IT SIMPLE WITH SOFTWARE With a shortage of skilled inspectors looming in the future of multiple industries, software solutions are extremely important when using a video borescope. Software is available to standardize inspection procedures to ensure consistency of both inspection and presentation of inspection results. Menu Directed Inspection (MDI) is a software solution that provides a guided inspection, where context is added automatically. All the identification data relevant to the task (inspector, site, date etc) is inputted before the inspection. The data image file is then tagged with annotations and filed within the borescope’s data capture system. A hard copy report is produced with a “click-to-report” feature. Software is key when it comes to sharing and storage visual images and its important

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the DICONDE (Digital Imaging and Communication in NDE) image standard is used to ensure long-term data utility and enables multi-modality communication. MEASUREMENT INCLUDED The measurement of flaws, discrepancies and clearances is just as important as their detection and identification; however measurement remains one of the most difficult aspects of using a video borescope. Measurements gathered by the commonly used stereo or shadow measurement technique are depth, length, area, point-to-line, multi-segment length and circle gauge. Operators must be highly trained and practiced to obtain reliable and repeatable results, which can slow down the overall inspection process. Recently, significant advances have been made in improving accuracy, repeatability and ease-of-use of video borescopes with the development of 3D Phase Measurement. This new technology provides accurate 3D surface scans using a single probe tip, saving time during the inspection process. Now a 3D scan can be captured rotated and zoomed to provide enhanced indication of the size and shape of the indication. CONCLUSIONS There have been many advances in remote visual inspection over the years. Image quality improvements, software and easy-to-implement measurement techniques can provide fast, accurate results with more comprehensive imaging to improve to allow smarter more efficient inspection.

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Change the way you conduct remote visual inspections with 3D Phase Measurement from GE’s Inspection Technologies business. Combined with the world-class XLG3™ VideoProbe®, 3D Phase Measurement streamlines the inspection process by allowing you to see a 3D view of the entire surface scan and measure defect size without FKDQJLQJWKHSUREHWLS:LWK'3KDVH0HDVXUHPHQW3UR¿OH9LHZWKH'LPDJHFDQEHURWDWHGDQGPDJQL¿HGIRU H[WUHPHO\DFFXUDWHUHVXOWVDQGDPRUHHȻFLHQWLQVSHFWLRQSURFHVV

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See a video demo on your phone To watch, snap a photo of the icon

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Buying a Previously Owned CMM T

here are many different ways to purchase used manufacturing equipment, including CMMs. Before you start this journey, there are some fundamental questions that you should answer before you consider the purchase of any CMM, whether new or used, because a machine that doesn’t meet your measurement needs is no bargain, no matter what the price. This quick checklist is a simple needs analysis you can complete before you start your search: What size of machine do you need? Determine this by thinking about the largest part you need to measure and adding clearance area for probing. What are your accuracy requirements? Study prints that contain the tightest tolerances for size, true position and form. Based on the complexity and variation of parts, what type of probe head is required? Fixed, rotating, touch trigger or scanning. What are your individual preferences? Likes and dislikes about current or past systems

or software you have worked with. This list is over-simplified, but ensuring you’ve done some basic homework before you buy will help narrow down your search to machines that will best meet your needs. COMMON RISKS WHEN BUYING A USED CMM When buying a CMM from an open-market source such as eBay, bankruptcy auctions, a broker or a third party service provider, there are many potential risks. Here are top five most common. 1. Unknown Damage to the Machine – With limited time or no ability to have someone knowledgeable to inspect the equipment, you run the risk there is significant hidden damage. Repairs can be expensive. 2. Other Costly Upgrades – Software, firmware, air hose or electronic upgrades could be required. 3. Legal Software – Most software is licensed, not sold. If the software with the machine is “used” there is a high probability that it won’t be legal unless the license is officially transferred to you. The software is also often out-of date and might not be supported. 4. Hidden Costs – Packing, transportation, installation, calibration are often not part of the selling price. To get the machine usable, significant expense and additional hassle is required. 5. Uncertain Market Value – There is no “blue book” for CMMs making it dangerous for the uninformed buyer. Often the seller isn’t likely to know how to fairly price the machine or even know if the machine is a good candidate to own as a used CMM. Used CMMs are not good candidates for purchase if parts & service are unavailable and if software cannot be upgraded. Finally, there is always a danger in buying something used from someone that can’t back the purchase. A “great deal” often isn’t so great when all the extra costs to get the machine running properly are added in.

Brown & Sharpe Globals are popular in the preowned CMM market.

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THE SOLUTION: BUY FROM AN OEM The only real peace of mind and hassle free experience when buying used CMMs comes when you purchase directly from the original OEM that built it. Many OEMs

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are thoroughly checked inside and out by the people that built them to begin with, plus all the original service records are often available. There is no effort because the purchase of a preowned CMM is completely turn-key. All the details are handled from shipping to installation and calibration. Finally, each system comes with full warranty and a 100% guaranteed legal seat of the most up-to date software. Preowned CMMS offered by Hexagon Metrology are backed by the strength and resources of the largest service and technical support team in the business. Assessing condition of wiring, hoses and bearing ways helps determine the market value of a preowned machine.

have used equipment divisions that refurbish and sell used machines that are good candidates for ownership. Hexagon Metrology is the premier OEM in the preowned CMM business. By providing a competitively priced, all-inclusive preowned CMM package, all the risk, effort and hidden costs are removed from the equation. All the risk is removed because the preowned machines offered

Contact Information: Hexagon Metrology, Inc. 800-274-9433 www.HexagonPreowned.com

Pre-owned CMMs, we buy and sell Buy with confidence from the OEM f/DUJHVHOHFWLRQRISUHRZQHG&00V f3HDFHRIPLQGDQGKDVVOHIUHHH[SHULHQFH f1RKLGGHQFRVWV f
Hexagon Metrology, Inc. _ZZZ+H[DJRQ3UHRZQHGFRP

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March 2011 | How To Guide | QUALIT Y 17HT

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How to Ensure Effortless, Ongoing ISO 9001 Certification and Perpetual Audit Preparedness By Paul Leavoy Writer and Researcher [email protected] 416.599.6009 x283

ISO

9001 audits can be a long, exhaustive and sometimes stressful process – unless an organization has implemented a software solution to streamline its quality management system (QMS). When quality management audits commence, too often the following situation occurs: Auditors arrive and are handed a file of quality-related documentation on paper. Alternatively, auditors are pointed to an array of disparate, siloed software systems (e.g. spreadsheets, Lotus Notes, etc.) In either case, auditors and quality managers can spend hours and often days poring through documentation and data to ensure an organization conforms to all ISO 9001 certification requirements. There are a number of problems with this process. Not only is a tremendous amount of time, effort and resources required to execute internal, external and customerinitiated audits, but all ISO conformance information is contained in separate compartments that are not integrated. Extensive manual effort is required to pull essential information – including documentation identifying QMS processes, resources, personnel, infrastructure and more – from these ‘siloed’ repositories of information. Further, with this approach, ensuring an organization is prepared for quality audits (which may occur at any point through the year, multiple times a year) can be a full-time responsibility as personnel

18HT QUALIT Y | How To Guide | March 2011

ensure ISO certification documentation is organized, accurate, and up-to-date at all times. But there’s a better way. Streamlined software alternatives enable organizations to automate many of the processes associated with QMS information management and render all quality audit-related materials and information up-to-date, accessible and transparent so ISO 9001 audits are transformed into a quick, painless, stress-free process. With the right quality management software solution, all documentation related to ISO 9001 certification is kept in one centralized location, accessible to quality managers and other personnel across a location, multiple business units, or companywide with the click of a button. Further, all quality metrics – including quality nonconformances (QNCR), supplier nonconformances (SNCR), and all other key performance indicators (KPI) – are displayed on real-time dashboards and scorecards, providing personnel and auditors an 360-degree, at a glance view of the complete status of a quality management program.

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Part of the appeal of a streamlined QMS software alternative, such as that offered by Intelex Technologies, is that the right solution represents a ‘two-click conformance’ approach to quality management and ISO 9001 certification. With this approach, any metrics, documentation or other material pertaining to quality management can be accessed with no more than two clicks of a mouse in a centralized, web-based database.

offering. All Intelex applications work within a centralized, web-based database and essentially ‘speak’ to one another, issuing collateral notifications and alerting employees when any requirements are unfulfilled. And critically, organizations consistently boost efficiency, save time, and automate audit preparedness by streamlining quality management within our centralized, web-based systems.

Essentially, with the right QMS software, the whole notion of ensuring audit preparedness becomes a thing of the past. Automatic, escalating email notifications alert staff of any pending or overdue quality-related activities and nonconformances, and comprehensive, real-time scorecards highlight any incomplete ISO 9001 requirements, ensuring nothing slips through the cracks. With Intelex quality management solutions, all ISO 9001 requirements (e.g. Quality Objectives and Targets, Quality Policy, Monitoring and Measuring, etc.) are mapped directly to a component of our software

Paul Leavoy is a writer and researcher who focuses on EHS and qualityrelated issues affecting businesses around the world.

Who knew it could be this easy? Quality Management Software that enables effortless ISO 9001 conformance. • Enable anyone, anywhere, at any time to submit, store and access data. • Automatically tabulate and generate audit reports with the click of a button. • Ensure ongoing, stress-free preparedness for internal and external quality audits. • Streamline data collection processes with task management and email notifications. • Get a 360-degree, real-time view of your quality program from a comprehensive management dashboard.

Free Trial Access Call us at 1-877-932-3747 or request free trial access online at www.intelex.com/qualitymag

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March 2011 | How To Guide | QUALIT Y 19HT

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How To Get the Most Out of Your Micro Hardness Tester he Vickers hardness test provides the hardness (HV) of a material by calculating the force over area of the indentation. The formula is HV = 1854.4 x Force/d2 where the force is in gf. and d is the diagonal length in microns. There are variations to change the formula for macro Vickers and the Knoop scale as well but the idea is similar. The Knoop formula uses the projected area while the Vickers scale uses the surface area calculation. Most digital testers do this calculation as well as averaging the diagonals for you and most non-digital testers are supplied with look up tables to convert the filar units to the correct hardness.

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There are 3 main components to the hardness tester itself and each one needs to be in the proper working order to get the most accurate measurements from your tester. The first component is the loading system of the tester. The tolerances of the forces and speeds at which indenter contacts the sample are all specified in the ASTM E384-10 document for Vickers and Knoop testing. The manufacturer should certify that all these criteria are met when the tester is produced and there is little that you as the operator can do to check these individual components. Therefore it is important to validate your tester on a regular interval as defined in the E384 document.

overlooked component is the optical measuring system. And please include the operator in that system! The main component is the objective lens which should be chosen for magnification according to the recommendations listed in the ASTM specifications. These lenses usually are very close to the sample surface and may accidentally come into contact with the sample causing scratches or even cracking. This may only show up as a slightly fuzzy image or just not as bright. Care should be taken when removing any lens because lens position is important for centering and some manufactures use a spacer that determines both magnification and indenter travel. Lenses cannot generally be repaired. Cleaning either the lens or the eyepiece is not difficult but only a small amount of lens cleaner (1 drop or less) should be added to the lens tissue, not directly to the lens. Extremely dirty lenses might require two or more tissues. Lenses internal to the tester that are dirty are

The indenter itself is also very difficult for the user to validate other than to check for abnormalities in the indentation like rounded corners or a larger offset where the faces meet at the tip of the indentation. Sometimes the indenter becomes coated in oil and will leave a rainbow effect on the indentation making it difficult to measure correctly. A little alcohol on a cotton swab can be used to clean this but it is often easier to place a piece of paper between the sample and the indenter and make a test indentation. Of course this indentation should not be used for measurements. Assuming that the mechanics of the testers are working properly, the last and most commonly

20HT QUALIT Y | How To Guide | March 2011

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probably best left to service or calibration technicians. Despite the flat field objectives lenses commonly in use, centering the indentation in the field of view will produce the most accurate readings. Check your manual but most testers allow the optical system or indenter mechanism to be adjusted to align to one another, usually with a target or crosshair and a zero mark. This will also save time hunting around for the correct indentation. The illumination system of the tester usually allows for alignment of the bulb to the optical path. Most testers use a ribbon filament halogen bulb that can be centered by gently removing the entire filar measuring unit, (the complete eyepiece assembly) and adjusting the filament image now visible in the open eye tube. Some instruments have lamp houses that are adjustable with thumb screws or set screws and some newer machines are non-adjustable due to improved manufacturing technology of the bulbs. A second way is to position the indentation in the very center of the field of view and look at the 4 faces of the indentation. They should be equally illuminated. If you have an adjustable aperture diaphragm, it should also be adjusted properly by stopping it down until a slight amount of the diaphragm is visible in the eye tube (with the entire filar eyepiece removed). The aperture technically should be adjusted every time a lens is changed but the lens used for the actual measurement is the only required setting. Most older testers are fixed to the highest power measuring magnification.

point. Remember to always use the same side of the line to measure. For units with 2 filar lines, open the lines so that just a small gap is visible between them and focus the eyepiece on the edges of the gap. In this case, remember that you are going to zero out the distance between the filar lines as your next step. Care should be taken not to force the filar lines into each other as damage can occur. Some testers remember this zero point even when the unit is turned off but it is wise to check the zero point frequently as well as the eyepiece correction. With the microscope portion of the hardness tester correctly aligned and the eyepiece tuned to the users’ eyesight, greater repeatability and accuracy are possible from just a bit more effort. The ASTM standard E384-10, available for purchase at www.ASTM.ORG , also has recommendations for other common problems encountered during the test method such as these: Minimum material thickness. The part should be 10 times the penetrated value of the indentation. For Vickers, penetrated value is about 1/7th of the diagonal length and approximately 1/30th of the diagonal for Knoop testing. Minimum diagonal length. Measurements below 20 microns in length require special precautions and equipment. Minimum space between indentations or edge of sample. Test piece surface requirements. The smaller the indentation, the better the surface needs to be.

Lastly and the most importantly is the operator. Each user has different eye sight and the eyepiece needs to be corrected accordingly. This difference often causes the largest discrepancy between user’s measurements because they are looking at the same indentation differently. Their eyepiece should be adjusted, such that the operator can see the filar lines in the eyepiece as clearly as possible. This is like a diopter for a camera or like the values listed on regular eyeglasses. For units with only 1 line or reference mark, the operator should rotate the eyepiece lens to focus on the line or

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Walter Wardzala is the Corporate Material Testing Specialist at Mitutoyo America Corporation. He is actively involved with ASM and ASTM. If you have any questions regarding Micro Hardness Testing or any type of hardness testing, you can contact him at 847-682-1628 or email [email protected].

March 2011 | How To Guide | QUALIT Y 21HT

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Leveraging Process Approach Auditing for ‘Bottom-Line’ Results By Aaron Troschinetz, NSF-ISR Technical & Certification Services Manager

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egardless of their sector, organizations that subscribe to quality management system (QMS) standards and schemes are increasingly demanding more value from the third-party audit services they receive from certification bodies (CBs). Many of these organizations are using audit services to drive organizational change throughout their respective companies. The audit can be a ‘second set of eyes’ which helps to gain insight into how business processes can be optimized to give them a competitive advantage. The challenge for every certification body is simple: How do CBs take the process audit approach with QMS standards and schemes and leverage it to increase value for organizations to achieve ‘bottom-line’ results? The process audit approach taught organizations which use ISO 9001:2000 (now ISO 9001:2008), that they need a deep understanding of their business processes, along with customer requirements and appropriate inputs/outputs. The result is higher customer satisfaction levels through the plan-do-check-act (PDCA) model. Senior management commitment must be in place to ensure continual improvement of the overall QMS. Other sector standards or schemes utilized these requirements as a framework to further define the process audit approach (ISO/TS 16949, AS9100/10/20, etc.). This helped organizations to reach higher levels of understanding regarding criteria such as scorecards, customer-driven key performance indicators (KPIs), organizational metrics, etc. which clarified their overall importance. For the purpose of this article, we will focus on KPIs as a measurement of performance for the QMS. These KPIs represent a tangible indication, and insight to the auditor, of how well an organization is performing in accordance with customer requirements. As CBs continue to integrate KPIs into their audit activities, many different approaches are being attempted by auditors to utilize this information using the process audit approach. Some auditors treat KPIs and QMS as two separate inputs which is incorrect because they should be reviewed in tandem with the organization’s process. This approach disrupts the

22HT QUALIT Y | How To Guide | March 2011

inherent connection between the organization’s processes and these measurements which exist, regardless of the audit activity. Some auditors take this KPI information at face-value as an indication of a breakdown or gap in an organization’s QMS. The auditors will issue their CARs almost in parallel with the KPIs. This approach was never intended with this KPI information, The true breakdown does not exist with the KPI but within the process itself. Auditors who consistently apply the appropriate parallel connection between the KPI performance levels and an organization’s processes are using this information correctly as a guide to prioritize the appropriate audit trail. The next step is for the auditor to provide an audit line of questioning to help peel away the layers of the organization’s QMS to determine its deficiencies or CARs. The following is an example of the appropriate application of KPI performance in an organization’s processes: Organization X is achieving a 92 percent rate of on-time product delivery. Its customer has defined an appropriate performance level to be 98 percent on-time product delivery. The organization is clearly missing this customer-defined target. The auditor in this situation should investigate the underlying reasons why KPI achievement is not being realized (for example, issues with customer order entry, product realization, or servicing/shipping). Appropriate follow-up questions include: What is management’s commitment level to realize these KPIs within these processes? Are the KPIs well understood by all areas supporting these processes? Are the supporting KPI data properly analyzed for variation and understood for appropriate root causes, necessary containment or corrective action? This line of questioning gives an indication of which process features to investigate, allowing the auditor to uncover the underlying deficiencies and corrective actions needed. As auditors utilize the connection between the KPI performance level and the organization’s processes outlined above, many different audit techniques may be used. Each technique can be tailored to fit the organization’s QMS structure/organization or an

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auditor’s respective skill set. An auditor may focus on the process interfaces that are a subset of the KPIs as an initial point of investigation such as, the interface between customer order entry and product realization or the interface between product realization and servicing. As auditors can attest, process interfaces are often the most common source of failures within an organization’s QMS because inputs/outputs are frequently not handled appropriately. Auditors also deploy a tool known as the process turtle. They walk their audit interviewees through the identification of customer inputs/outputs as well as infrastructure, resources, control and KPI requirements so they can understand not only the process features but an obvious alignment point document with the standard being audited. The technique deployed should maintain the natural flow of a process approach audit into different areas of the organization’s QMS, to be successful at identifying failures that demand the organization’s attention. Once the auditor has determined the KPI information lead-ins to the organization’s processes and starts to uncover the next layers of QMS using appropriate audit techniques, the next challenge is to summarize information into terms of real value to the organization and appropriate CAR identification. While many auditors appreciate requirements for their clarity and ‘black and

white’ prescription, this can often be the point at which the auditor and organization struggle to make a connection. Auditors should be going back to the KPI, defining the KPI deficiencies in terms of what the organization has to gain. Examples of gains may include increased revenues, expansion of potential business opportunity, etc. and aligning the gains with the observed process deficiencies. This connection can be clearly supported through the auditor’s identification of the evidence and description of the CAR to the underlining supporting requirement it is being written against. As organizations continue to require more value from their third-party audit services, CBs are linking their process thinking to the supporting KPIs to allow management or organizations to see their performance associated with them. Many organizations are already showing consistent signs of integrating business management systems into real-time KPI tracking systems. These types of systems provide a platform for fine-tuning process weaknesses, reallocation of supporting infrastructures and people. As this evolution continues, the CB’s challenge is to define real value achieved through their audit services. Organizations will choose continued business relationships with CBs that are able to innovate and offer more value through their audits.

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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March 2011 | How To Guide | QUALIT Y 23HT

Quality | HOW TO GUIDE

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How to Verify Alloy Materials Using Handheld X-Ray Fluorescence (HH-XRF) Ken Smith, Global Business Development Manager,

PR disasters, and possible injury or death. Many factors

Alloy & Specialty Markets

can lead to material mix-ups. Alloys can be:

Olympus Innov-X

• produced outside of its chemical specifications;

[email protected] • incorrectly marked by the manufacturer; lloy compositions are specifically designed for their

• misplaced in inventory,

end-use application and performance requirements.

• mismatched to a material specification sheet; or

A

An alloy’s composition has a direct impact on its corrosion resistance, mechanical characteristics and

• incorrectly selected during installation.

creep resistance. Because different alloy compositions can resemble one Unfortunately, alloy materials can be easily misplaced or lost during handling. Using incorrect or out-of-spec

another, visual inspection should not be relied on for identification, as it could lead to mistakes.

alloys can cause critical components to fail, resulting in lost production downtime, repair and replacement costs, lost or contaminated products, environmental and

24HT QUALIT Y | How To Guide | March 2011

Handheld X-Ray Fluorescence (HHXRF) analyzers are fast and ruggedized tools which detect alloy chemistry

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and grade. They are particularly suited for alloy materials due to the homogeneity of these materials and the presence of highly responsive elements. (Elements heavier than Sodium may be quantified with HHXRF; direct measurement of Carbon, Beryllium, Boron, or Lithium is not possible.) While not 100% compliant with metallurgical certification, using HHXRF is a broadly accepted and standard procedure for QA/QC and PMI (Positive Material Identification) programs. XRF is completely

Implementing a quality control program with HHXRF is a straightforward process involving:

non-destructive. And as the technology continues to

• Basic Training and SOPs for inspectors;

improve, its applications are also expanding. Alloy

• Certified Reference Samples to confirm analyzer

grades that are ~99% identical, such as SS-303/ SS-304/SS-321/SS-347, and 9 Chrome/9 Chrome + V, are easily sorted by elemental differences as small as 0.05%. The current generation of HHXRF analyzers is also being utilized to screen for residual content in low-alloy steels and light alloys, such as aluminum and magnesium alloys. These analyzers are also commonly used in aerospace and marine industries to screen titanium, copper, and even refractory containing alloys. HHXRF cannot completely replace lab certification testing at this time. However, unlike lab analyses, which must be paid for on a test-by-test basis, HHXRF represents an investment requiring only an initial capital cost. HHXRF tests only take a few seconds to complete and are completely non-destructive. The speed of HHXRF makes redundant testing a cost-effective and highly adaptable verification tool: • test every sample during receiving to verify incoming materials; and • test again during installation to detect any post-receipt material-handling errors.

(and operator) performance; and • Retraining and review of the XRF QC protocol, as required. ROI from a HHXRF Alloy QC program has many sources. Testing at receiving and installation during the final quality check reduce potential costs resulting from lost labor, catastrophic failures, material scrapping, and customer dissatisfaction. Many companies have also found that public relations and marketing practices benefit from implementing and advertising comprehensive and progressive HHXRF QA/QC programs. That’s because supplier reliability is critical to long-term success in building partnerships with customers. As a rule, every organization wants to avoid material mix-ups, which can impact process uptime and customer satisfaction. As a preventive measure, redundant HHXRF testing is a practical and cost-effective way to prevent material mix-ups at every stage of material handling.

A single lab test at receiving won’t detect downstream errors in fabrication or installation. The goal of redundant HHXRF material testing is not only to verify that the material is correct and to spec, but also to correct any errant processes that could cause mix-ups.

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March 2011 | How To Guide | QUALIT Y 25HT

Quality | HOW TO GUIDE

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How To Use an Ultrasonic Thickness Gage H

and-held ultrasonic thickness gages are an accurate, repeatable tool for nondestructively measuring wall thickness from one side of a part in both manufacturing and service environments. They can be used on metals, plastics, composites, ceramics, glass, and rubber at thicknesses from approximately 0.1 mm (0.004”) up to very thick sections of hundreds of millimeters or many inches. They work by measuring the time it takes for a pulse of high frequency sound waves to travel through the test piece. A small probe known as an ultrasonic transducer that generates and receives sound waves is placed on the surface of the part and acoustically coupled with a drop of liquid. The sound pulse travels from the contact surface to the inside wall and bounces back as an echo that is detected by the gage. Using that measured time interval and a

The 38DL PLUS is an innovative instrument that signals a new era in ultrasonic thickness gaging. Ideally suited for almost every ultrasonic thickness application, this handheld thickness gage is fully compatible with a full line of dual and single element transducers. The versatile 38DL PLUS can be used in applications ranging from wall thinning measurements of internally corroded pipes with dual element probes to very precise thickness measurements of thin or multilayer materials with single element transducers.

26HT QUALITY | How To Guide | March 2011

programmed speed of sound for the test material, the gage then calculates and displays its thickness. To obtain the best performance from an ultrasonic thickness gage, you should follow these simple guidelines:

1. BE SURE YOU HAVE THE RIGHT EQUIPMENT FOR THE JOB There are a wide variety of ultrasonic gages and transducers commercially available, with different capabilities. Any ultrasonic measurement system – a gage, a transducer, and a gage setup – will be able to measure across a specific range of thicknesses in specific materials as specified by its manufacturer, and unlike a caliper or micrometer the range will vary with different materials. Additionally, measurement accuracy will vary between different instruments and setups. Always consult the manufacturer’s range and material specifications when selecting a gage and transducer to

Micrometers won’t work in this classic application. Instead, the Models 35 and 38DL PLUS with a M208 transducer make a thickness measurement up to a calibrated accuracy of 0.001 mm (or 0.0001 inch) without breaking the glass.

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insure that it meets your needs.

work and how they are used, and discusses a number of specific gage applications. Please see www.olympus-ims.com/en/ndt-theory/thickness-gage/.

2. CALIBRATE SOUND VELOCITY For accurate readings, ultrasonic gages must always be programmed with the speed of sound in the test material. Most gages provide default velocity settings as a starting point, but for best accuracy you should always perform a velocity calibration using a sample of the actual material to be measured whose thickness is known. This is usually a very simple procedure that is described in the gage’s operating manual.

3. CHECK YOUR SETUP It is good practice to verify that your instrument is properly calibrated by measuring one or more reference samples of the part to be measured before taking data, especially in cases where a gage has been programmed with multiple setups for different transducers and materials. This normally takes only a few seconds.

4. APPLY COUPLANT Because sound energy at the frequencies used for ultrasonic gaging does not travel well through air, it is necessary to use a small drop of coupling liquid between the transducer and the test piece. Glycerin and propylene glycol are commonly used, but other common liquids such as water and oil often work well. Gel couplants are normally recommended when testing on rough surfaces, and special high temperature couplants are available if the test piece is hot.

The Models 35 and 38DL PLUS with a delay line transducer or immersion bubbler make accurate thickness measurements on both convex and concave surfaces of turbine blades.

5. HOLD THE TRANSDUCER STRAIGHT For best results the transducer should be pressed firmly onto the test piece, and in the case of curved surfaces it should be held straight and centered. Avoid rocking or tilting the transducer, which can affect accuracy. Springloaded holders are available to assist with transducer alignment when testing tubing and other sharply curved test pieces.

FOR FURTHER INFORMATION Olympus NDT provides a comprehensive collection of technical papers and application notes on both the theory of ultrasonic thickness gaging and on approaches for specific tests on its web site at www.olympus-ims.com/en/applications. Olympus NDT also offers a tutorial which provides a basic introduction to the theory and practice of ultrasonic thickness gaging, for both newcomers and more experienced users who would like a review. It covers basic ultrasonic theory, how ultrasonic gages

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Cylinder bores and many other cast metal parts or sound-attenuating materials can be measured with the 35HP and 38DL PLUS gages.

March 2011 | How To Guide | QUALITY 27HT

Quality | HOW TO GUIDE

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How To Choose and Use Styli By Dennis Bobo, Senior Applications Engineer, Renishaw

I

n military terms, the stylus is the “tip of the spear” when collecting measurement data with a probe, and with the proliferation of probes in manufacturing – on machine tools, CMMs, portable arms – and the many different types of probes – such as kinematic, strain gauge, scanning – selection and use of the stylus becomes critically important. This topic deserves more depth and detail than we can give in this space, but these core points provide an overview. For traditional kinematic inspection probes used on machine tools, ceramic stems and ruby ball styli are the first choice. For CMMs, steel and tungsten carbide

are fine for shorter stems, with ceramic or carbon fiber recommended for longer stems. Ceramic stems are lighter than tungsten carbide, have stiffness comparable to steel, and are thermally stable – ideal for use in a machine tool environment. The ruby ball is exceptionally hard and smooth, with excellent compressive strength and resistance to abrasion. Ruby balls are manufactured to various levels of precision defined by their grade, which relates to the maximum deviation of the ball from a perfect sphere. Any error in sphericity will increase CMM measurement uncertainty, and it is easy to lose as much as 10 percent of a CMMs accuracy this way. The two most common ball specifications are grade 5 and 10 (the lower number is better). The more accurate the CMM is, the more significant the effect of ball grade. We recommend standardizing on grade 5, and offer grade 3 (with sphericity of just 0.08 micron) for the most demanding applications. For strain gauge probes, particularly those used on machine tools, carbon fiber styli are recommended. Carbon fiber styli, whether hollow or solid, have low mass, making them best suited for use with sensitive strain gauge probes. Carbon fiber is the most common material for long styli and extensions, because it is stiff, light and thermally stable. Where metals are needed – for joints, knuckles, etc. – titanium provides the best combination of light weight, strength, stability and density. Styli for portable arm CMMs require robust design and construction. They utilize Grade 5 Zirconia balls that are highly fracture resistant. The balls are bonded to the high strength tungsten carbide stem with impact resistant adhesive, and special construction techniques have been incorporated to ensure the joinm is extremely rigid and virtually indestructible. Scanning probes, such as the SP25M CMM probe, introduce other variables that affect the choice of ball materials. Scanning produces a more aggressive type of surface interaction than touch probing, resulting in three interactive phenomena: debris accumulation, adhesive wear and abrasive wear. Debris is practically unavoidable, and is independent of the stylus ball or

28HT QUALIT Y | How To Guide | March 2011

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part surface material. It can be removed with a dry lint-free cloth. Adhesive wear involves the permanent transfer of material from one surface to the other through local welding or transfer of minute particles from one surface to the other. Adhesion of material will eventually degrade the form of the stylus ball and compromise measuring results. Abrasive wear involves the removal of material from the ball and part surfaces. Based on extensive testing in scanning applications, ruby is the best ball material for most applications, including stainless steel and titanium, but it can suffer adhesive wear on aluminum under extreme conditions. Silicon nitride is a substitute for ruby in extreme aluminum applications, but can suffer abrasive wear on stainless steel or cast iron. Zirconia is the best choice for scanning cast iron parts, though tungsten carbide performs well also. A few simple rules for stylus use can maximize accuracy for most probing applications: • Keep styli short and stiff - The minimum stylus

length will give optimum results. A longer stylus amplifies errors and introduces the potential for excessive bending. • Minimize the number of joints – Joints and extensions introduce potential bending and deflection points. • Keep the stem diameter as large as possible – Thicker stems increase the stiffness of the stylus. If a stem with small diameter is required, try to use an M4 extensiem with only a short stylth of the smaller diameter stem on the end. • Keep the stylus ball as large as possible – This maximizes the ball/stem clearance, reducing the chance of false triggers caused by “shanking out” on the stylus stem, and increasing the effective working length. A larger ball also allows a larger stem diameter, increasing the stiffness of the stylus. Finally, the larger ruby ball reduces the influence of a part’s surface finish on measurement results. RenishawDirect.com has more information on stylus selection and options, as well as the comprehensive range of precision-engineered styli for Faro arms, Zeiss probes and Renishaw products.

Contacts: Jeff Seliga Renishaw Inc. 5277 Trillium Blvd., Hoffman Estates, IL 60192 Tel: 847.286.9953 Fax: 847.286.9974 [email protected] Ray Kemble Kemble & Rude Communications, Inc. 4242 Airport Rd. Cincinnati, OH 45226 Tel: 513.871.4042 Fax: 513.871.4895 [email protected]

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March 2011 | How To Guide | QUALIT Y 29HT

Quality | HOW TO GUIDE

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Looking for Noncontact Inspection?

S

-T Industries, Inc. began manufacturing precision measuring tools in St. James, Minnesota, in 1942. S-T is still known worldwide for its lightweight tubular frame micrometers with standard models available up to 96 inches. S-T also manufactures a complete line of solid frame micrometers, specialty micrometers, inside and depth micrometers and has a complete line of measuring tools available. S-T has manufactured thousands of modified and special measuring tools over the past 66 years and welcomes your inquiries for specials. S-T also manufactures a complete range of optical comparators, horizontal and vertical types in screen diameters of 14”, 16”, 24” and 30”. All models feature Acu-Rite® precision glass scales with a resolution of

30HT QUALITY | How To Guide | March 2011

.00005”/.001MM and a choice of Quadra-Chek® digital readout systems including the QC-100, QC-200, QC-300 and QC-5000 series. The 24” and 30” models include standard motorized joystick controls in the X and Y axis travel and are available with fully automatic CNC controls. Smaller units are also available with motor controls and fully automatic CNC controls. Special inquiries are also welcome. S-T has supplied units with extended vertical travel, special long focal length lens and X-axis travel up to 30 inches. S-T also manufactures a series of video inspection systems with stage travels of 4”X8”, 4”X12”, 6”X12” and 12”X12”, with larger sizes available on request. All video systems feature 3OX-180X zoom lenses, high resolution color cameras and flat screen LCD monitors, LED lighting, Acu-Rite® high precision glass scales with

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30" OPTICAL COMPARATORS MADE IN U.S.A.

.00005”/.001MM resolution, a choice of all Quadra-Chek digital readout systems are available for manual operation, motorized X, Y and Z motions or with fully automatic CNC controls. All S-T optical comparators and video inspection systems include factory installation, training, certification to NIST and a two-year warranty on parts and labor at no extra charge and are manufactured in the U.S.A. at our factory in St. James, Minnesota.

“5600” SERIES 30'' OPTICAL COMPARATOR High precision 9" x 12" measuring stage travel with .00005"/.001mm resolution. Optional 7" x 20" and 7" x 24" travels available. • Motorized X and Y axis with joystick control. • Optional 6-position power lens changer. • Duplex surface illumination. • Digital screen protractor with readings to 1' or .01° with rotating steel ring. • Available CNC option. • Erect Image •

For more information call us at (800) 326-2039 fax (507) 375-4503 email [email protected] or visit our web site at www.stindustries.com

“2600” SERIES 30'' OPTICAL COMPARATOR High precision 9" x 12" measuring stage travel with .00005"/.001mm resolution. Optional 7" x 20" and 7" x 24" travels available. • Motorized X and Y axis with joystick control. • Optional 6-position power lens changer. • Duplex surface illumination. • Digital screen protractor with readings to 1' or .01° with rotating steel ring. • Available CNC option. •

301 Armstrong Blvd., St. James, MN 56081 Phone: 1-800-326-2039 Fax: 507-375-4503 Internet: www.stindustries.com E-mail: [email protected]

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March 2011 | How To Guide | QUALITY 31HT

Quality | HOW TO GUIDE

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How To Close the Loop on the Digital Manufacturing Workflow C

AD-Based inspection software helps CAD, GD&T (Geometric Dimensioning and Tolerancing) datums, and measuring devices work together to ensure design intent and eliminate the need for 2D inspection drawings, while closing the loop on digital workflow. These are all important considerations when moving towards a Model-Based Definition (MBD) environment. CAD-Based inspection is a good practical first step toward the goal of a complete MBD environment. The central concept embodied in MBD is that the 3D CAD model provides all of the detailed product information necessary for all aspects of the product life cycle. Engineers have wanted to harness the power of MDB for years. In a 2005 presentation, Terrence McGowan of Boeing, stated, “The 3D model should contain everything needed from design to manufacturing, in particular, GD&T.” What this means for manufacturing and inspection is that they pull all dimensions and tolerances from the 3D CAD model instead of a 2D paper drawings. Making the CAD model the authority removes ambiguity, conflict and doubt that arise when drawings and models co-exist. With authority bestowed on the CAD model, MBD eliminates errors that result from referencing an incorrect source and makes processes more efficient. No more searching to determine correct revision levels.

Verisurf X CAD-Based inspection software uses ASME Y14.5-2009 GD&T symbols as part of its CAD interface. CAD-based GD&T annotations can be imported as part of the CAD file if supported by the program, or added to the CAD model with Verisurf X.

32HT QUALIT Y | How To Guide | March 2011

In the context of the enterprise, the benefits are many and diverse. MBD is the single information source to build and maintain products, and it integrates into processes from cradle to grave. Providing definition for operations throughout the product lifecycle, there are simply too many benefits to name. Yet, to summarize MBD’s impact, one only has to look at the goals of leading aerospace companies when they began their pursuits of MBD: • Improve quality • Accelerate time-to-market • Decrease time and expense GD&T and CAD-based inspection is a great place to start when moving towards MBD. It moves the CAD model from design to a manufacturing orientation. It opens the door to many advantages where software can automate and validate steps in the simulation, manufacturing and inspection processes. CAD-BASED INSPECTION AND GD&T A necessary component of CAD-based inspection and the MBD approach to product design is GD&T, a universal symbolic and tolerancing language. Last updated in 2009, GD&T has been rigorously studied and applied by thousands of manufacturers around the world. It is often considered essential for communicating design intent — that is, that parts from technical drawings have the needed form, fit, function, and interchangeability. The recent update includes changes in feature design, datum references and degrees of freedom, surface

Verisurf X illustrates high and low tolerance deviations on associated CAD model GD&T specs.

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boundaries and axis methods of interpretation, profile tolerances, the symbols and modifiers tools. In manufacturing the direction of CAD is to 3D, however not all CAD programs provide intelligent GD&T data. Here, “intelligent” means computer readable, thereby capable of feeding downstream applications. There are two GD&T definition-data formats. Potentially confusing, both are labeled “3D annotation,” but one format is purely for display, while the other provides intelligence back to the CAD model. The distinction is that in the display format, Tolerancing associated to the model is in the form of text. In other words, humans must interpret the GD&T information, opening the door to potential errors. The display or presentation format is similar to typing a math equation in Microsoft Word. It conveys information, but the computer cannot use it in calculations. In conversation, this approach is commonly referred to as “decorating the model.” What makes the effort of applying GD&T to 3D models worthwhile? As part of the MBD approach, it helps users leverage data throughout product development, cutting time from processes and improving them, while avoiding investment in 2D drawings. It can even be said that 3D GD&T data provides a form of “artificial intelligence” for manufacturing and inspection.

Verisurf X provides a common software platform to drive all digital metrology devices. Benefits include, reduced training time across multiple devices, consistent reporting formats, and support for upstream enterprise databases.

3D CAD-BASED INSPECTION GD&T defines quality requirements, and inspection then confirms these requirements are being met. For CAD-based inspection to occur, there must be GD&T representation and the inspection software must be able to import the data from the native CAD software. When intelligent GD&T data is not available, users must be able to add it to the CAD model in the inspection software. CAD-based inspection involves inspecting physical part measurements against the CAD model. This process can be dependent or independent of how or where Tolerancing is defined on the CAD Model. Consider, for example, inspection software such as Verisurf X from Verisurf Software Inc. It connects to and controls measuring devices such as scanners and laser trackers as well as stationary and portable coordinate measuring machines (CMMs). It also accommodates both presentation and intelligent GD&T specs from CAD models. Intelligent GD&T datums are imported directly from the native CAD software with the 3D model and provide nominal dimensions. For presentation annotations, the quality or manufacturing engineer uses Verisurf to add GD&T specifications to the 3D model. Importing information from a native CAD package as a 3D CAD model with GD&T representation is a good example of moving towards an MBD environment.

Verisurf X uses the CAD model as the nominal definition to generate custom reports in industry standard formats, including GD&T constraints and color deviation maps. A Database Write feature in the program formats and sends inspection information to SPC applications and PLM databases used by major manufacturers. The feature also supports Microsoft Access and SQL Server database formats for combining Verisurf inspection data with numerous enterprise databases.

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March 2011 | How To Guide | QUALIT Y 33HT

A Powerful, Multi-LED, Broad-Beam UV-A Inspection Lamp!

TRITAN™ 365 Multi-LED UV-A Inspection Lamp

Weigh s Just 1 lb!

Unlike conventional HID inspection lamps, the TRITAN™ 365 features three powerful ultra-high-flux UV-A LEDs that run cool to the touch! The lamp’s broadbeam profile provides wider coverage than standard UV inspection lamps, while its compact size allows access into areas inaccessible to larger lamps. The TRITAN™ 365 is the ideal lamp for all your NDT inspection applications!

Features :  Nominal steady-state UV-A intensity of 5,500 μW/ cm2 at 15 inches (38 cm)

 Large 4 inch (10 cm) diameter coverage area, with a minimum UV-A intensity of 2,000 μW/cm2

 30,000 hour LED life  Convenient white light LED illuminates dark work areas with just a flick of a switch!

 Instant-on operation. Lamp reaches full intensity immediately!

 Electronic Intensity Stabilizer ensures consistent LED performance

 Built-in fan keeps LEDs cool to maintain optimum light output during extended use

 Choice of 8 foot (2.4 m) or extra-long 20 foot (6.1 m) power cord with AC plug. Available in 120V, 230V, 240V and 100V models.

 Meets ASTM UV-A intensity specs for FPI and MPI

For even greater versatility, order the TRITAN™ 365M battery-operated AC/DC lamp kit. Comes complete with TRITAN™ 365M UV lamp, rechargeable NiMH battery pack with adjustable shoulder strap and belt loop, AC and DC cord sets, smart AC charger, UV-absorbing spectacles and soft carrying case. AC charger available in 120V, 230V, 240V or 100V versions.

For more information,

1-800-274-8888 www.spectroline.com call

or visit