Until recently, conventional 3-axis CMMs proved largely sufficient. A probe attached to a third moving axis measured a part’s physical characteristics. But slower cycle times, limited flexibility [5 to 7 1/2 degrees of polarity] and lack of mobility have proved problematic in an Industry 4.0 environment. Rigidity and high costs have made custom gauges—another type of measurement instrument— less attractive since the tool can only inspect the part it was designed for.
American singer, actor, pianist and comedian Jimmy Durante was known for two things: his distinctive gravelly speech and his prominent nose which he referred to as the Schnozzola. He coined the phrase, “The nose knows.” The ‘nose’ of 5-axis measurement technology also ‘knows’ when it comes to measuring complex part surfaces. The REVO-2 shoulders the fast motion required for higher throughput while the CMM moves in a slow, linear manner. The REVO-2’s flexible tip-sensing probe boosts accuracy and performance.
Expo Manufactura 2018 was held in February and drew more than 12,500 visitors to Monterrey, Nuevo León. The 3-day event targeted Mexico’s manufacturing and processing industries and featured the technologies and processes needed to support automotive spare parts, aerospace, energy, medical devices, electronics and home appliance supply chains. More than 300 companies exhibited their products.
A new year has most people thinking about resolutions, fresh starts and the need to purge closets, basements and garages of items destined for the Goodwill. We're here to tell you that tidying up also plays a role on the shop floor. Performing annual preventative maintenance and calibrations on your coordinate measuring machine (CMM) should be an important part of a company’s housekeeping. There are many factors you should keep in mind when doing these annual checks - so read on!
A lot of manufacturers are asking: Is Industry 4.0 actually here? Reports acknowledge that 2017 was “a breakthrough year for digital factory solutions. Additive manufacturing, Industry 4.0, and digital transformation all gained momentum, cementing the need for factory Ethernet if manufacturers want to compete globally.” Predictions for 2018 trends include IT and OT convergence, the rise of smart mechatronics, big data and analytics and the emergence of intelligent automation. So where do coordinate measuring machines (CMMs) fit in?
In the 1959 film Some Like It Hot, two male musicians witness a mob hit and flee the state disguised as women in an all-female band. Of course, things begin to heat up as further complications set in. Job shops are also looking to avoid the heat or "coefficient of thermal expansion" when it comes to needing a mobile coordinate measuring machine (CMM) that can withstand temperature variations on the production floor.
If you're a regular reader, you know we've recently explored the automobile, airplane and medical device markets and the way these manufacturers use CMMs. We've summarized some of those key points as well as some additional information into a new ebook, which we'd like to introduce with this blog. Let's start with the airline industry!
The Reshoring Initiative was founded by Harry Moser in 2010 to bring manufacturing jobs back to the U.S. In 1985 Moser served GF Machining Solutions (formerly known as GF AgieCharmilles) as president before retiring in 2010 as chairman emeritus. His passion for manufacturing in America has fueled his reshoring efforts which have been recognized nationally. Moser was inducted into the Industry Week Manufacturing Hall of Fame in 2010 and was named Quality Magazine’s Quality Professional of the year in 2012.
During the last few years Industry 4.0 has ushered the Internet of Things (IoT) and the Industrial Internet of Things (IIoT) onto production floors across the U.S. According to IHS Markit, the number of connected IoT devices worldwide “will jump 12 percent on average annually, from nearly 27 billion in 2017 to 125 billion in 2030." Simply put, the IoT is a massive network that connects people, machines and devices. So what does that mean for quality?
FABTECH is North America's largest metalforming, fabricating, welding and finishing event, held every November at one of three rotating venues. This year, FABTECH opened to vendors, exhibitors and visitors in Chicago at McCormick Place. With more than 750,000 sq. ft. of floor space dedicated to approximately 1,700 world-class suppliers and the latest in industry products and developments, you're bound to see some interesting things.
Medical device makers have a lot to keep up with these days when it comes to measuring parts. Adoption of additive manufacturing is growing. 3D printed parts must meet dimensional integrity standards but may not be suited to conventional measurement methods. Casting, plastic and metal injection molding and electrical and chemical erosion techniques also create components too complex for traditional measurement methods. So what is a manufacturer to do?
These days baby boomers are more active than ever. As 70 becomes the new 50, the demand for medical implants is on the rise. According to the American Joint Replacement Registry, “hip and knee implants account for more than 85 percent of the joint reconstruction and replacement market.” The American Joint Replacement Registry also notes that more than 7 million Americans have had a knee or hip replacement surgery.
The prismatic or 3D parts that are used in joint replacements - along with other medical devices like stents and their coatings or instruments like scalpels - are tough to manufacture and even more difficult to inspect. Myriad geometries and materials contribute to the challenge of producing parts that meet stiff regulatory requirements. Meeting delivery deadlines can also present another snag if a manufacturer doesn’t have a fast and accurate inspection system.
The medical device market is moving at the speed of sound. Could quality get left behind?
These days the medical device market reads a little bit like an epic science fiction novel with a large cast of characters. Longer life expectancy coupled with an active lifestyle now defines 70 as the new “middle age.” Increased availability of healthcare, advances in real-time analytics, the Industrial Internet of Things (IIoT) and the integration of devices with evolving technologies is driving strong growth and rapid changes for manufacturers. The global market for medical device outsourcing is expected to reach $40.8 billion by 2018. As a result, the pressure to accelerate design and production to move products to market faster, more efficiently and more cost effectively is also growing.
Since AIMS ranks customer service right next to superior product quality, I was interested to come across a new survey emphasizing the importance of both. The survey, conducted by iBASEt, targets lean champions, continuous improvement leaders, senior manufacturing execution system (MES) administrators and senior manufacturing engineers. The results are worth exploring.
I'd just graduated from high school when I saw Star Wars in 1977. I basically witnessed the moment that cinematographer George Lucas changed the way movies are made by pioneering a new direction for computer animation and digital effects. Now, 40 years later, digital IQ technologies are changing the way manufacturers operate. Consider for example the "smart factory." Its goal is to help companies gain significant real-time quality, time, resource and cost advantages from their production systems. Coordinate measuring machines play a key role as parts become more complex, with tighter tolerances and shorter customer lead times. But don't just take our word for it - let's hear from Pratt & Whitney's Wayne Nye.
The Reshoring Initiative is an organization dedicated to showing manufacturers that local production can translate to lower cost of ownership of purchased parts and tooling. In addition to dispelling manufacturing "urban myths," the Initiative, founded in 2010, “trains suppliers to effectively meet the needs of their local customers by giving them the tools they need to understand how to sell against lower priced offshore competitors.” But as much as this term is used - do we all understand what it means? And why bother?
Like offline programmers, individuals with the competence to calibrate a coordinate measuring machine, that is, make precise adjustments for particular functions or features, are difficult to find these days. This lack of skilled individuals has manufacturers turning to CMM OEMs to take on calibration and certification tasks. The demand, particularly among aerospace and defense, automotive, power generation and electronics manufacturers, is expected to expand the calibration services market to an estimated $6.84 billion by 2020. Tighter quality requirements, proactive maintenance and stricter government regulations are contributing to market growth.
Photo courtesy of OSX, https://commons.wikimedia.org/w/index.php?curid=12890947
In the 1982 blockbuster E.T. the Extra-Terrestrial, Elliott utters the memorable line, “One thing. I have absolute power. Say it,” just before he introduces E.T. to his brother Michael. Car makers are also asking for accurate absolute measurements, especially when it comes to Body in White (BIW) assembly.
According to Wikipedia, "Body in white or BIW refers to the stage in automobile manufacturing in which a car body's sheet metal components have been welded together. BIW is termed before painting & before moving parts (doors, hoods, and deck lids as well as fenders), the engine, chassis sub-assemblies or trim (glass, seats, upholstery, electronics, etc.) have been assembled in the frame structure." As you can see, BIW involves many parts, and metrology plays a key role.
The U.S. Army Drill Team uses bayonet-tipped 1903 Springfield rifles to perform intricate, synchronized routines with split-second precision and timing. But the HHC, 4th Battalion, 3d U.S. Infantry Regiment aren’t the only ones coordinating their movements. Coordinate measurement machines use a probe-tipped head that surveys part features with extreme accuracy. But have you ever wondered what the difference is between conventional systems that use indexing heads or fixed probes and 5-axis measurement technology?
The U.S. Bureau of Labor Statistics reported that Americans spent 39,243,750 hours in 2014 on yard work alone. Do you ever look at your own house or lawn and feel like your to-do list is endless? In the automotive and transportation industries, metrology needs also appear endless. Every part you can think of needs to be inspected at one point or another somewhere along the supply chain.
Auto makers are feeling the pressure of tightening margins and shorter turnaround times. Innovation continues to rapidly change the way parts are made. Also, automotive quality standards recently received a significant update, giving sector members one more thing to keep pace with. The challenge? Balancing innovation with safety.