360 SIMS – The Power of Large Data Set in

Automated 3D Metrology & Process Control

By Tal Vagman, Director Product Strategy

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Our Goal : Contribute to Integrated Quality Production

SM Stamped Parts

SM Subs

BiW Assembly Line

Closures subs

Body/Closure

Engine Cradles

General/ Final Assembly

Final Car inspection

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Sampling (Traditional CMM) 100% Inspection

Sampling off-line vs. 100% Inspection in-line

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Why measure Production Parts / Assemblies near or In-line ?

• Help bring dimensions closer to design intent (drive to nominal)

• Product Quality Monitoring, Process Control

• Continuous process improvements

• Pin pointing cause and guiding corrective action

• Historical analysis & archiving

Advantages

• Faster ramp up / problem solving

• Reduce rework, scrap, logistics, warranty cost

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Reduce variation

(dimensional volatility in production)Bring process to nominal or functional

(CAD or Virtual Master)

Process Control Motivation

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Product Quality Development & Monitoring

Upper reject limit

Upper spec limit

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Inspection Plan – Until today based on critical points only

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With 360 SIMS: Both Area & Critical Features Measurement

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Multi-Part Process Evaluation During Pre / Production

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Customer Standards for Product Monitoring / Process Control

OK – Within tolerance

Trending – Near tolerance limit

Out of tolerance

Measurement Error

Rejected – Stop the line

Flexible setting of control limits

- Each limit can trigger different action

- Limits can be changed according to

actual production situation

- Limits can refer to % of tolerance

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Dimensional Rules Management on Go / No go decisions

OK – Within tolerance

Trending – Near tolerance limit

Out of tolerance

Measurement Error

Rejected – Stop the line

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Distribute data to different users according to their specific needs

From the Cell to the Data users

In-line Station

In-line Cell

Data Users

Quality Control Room

Factory IT

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Measurement Cell: Data Distribution to Various User Needs

Operator Pass /Fail indicator

Automatic PDF Report

Automatic unified .cto

Export to Qdas, Quirl, custom

customer SPC / Reporting SW

On-screen Color Map analysis

Video of the day

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Production measurement results used for Part Inspection by

various Software (Customer, 3rd Party and Hexagon Metrology)

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Flexible Post Measurement Inspection / Analysis

Adding on full data set:

• Adding surface points

• Adding features / edges / dimensions

• Re-aligning with different settings

• Cross sections and adding dimensions

• Exporting all types of data / reports

Adding on our compressed data:

• Surface points, edge line points and dimensions

• Cross sections and 2D dimensions

• Exporting various types of data

• Generating Master part

• Generating reports

•

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Process Control Life Cycle & Identifying Different Situations

Stabilization during

Launch / ramp up

Controlling a

stable processAdapting limits according

To production stability &

tolerance

Handling less stable

points

Non stable critical points

Temporary / limited

rejections Or reworks

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Point and Area based Process Control / Server Based

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Process Control Tools (Features and Dimensions)

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3D Process Control Severity and Escalation

Inspection Results PLC Control/User Action

Automatic transfer to next station

Automatic transfer to next station with low profile alert

Automatic transfer to next station with wider alert

Automatic pause of transfer subject to user check

and decision

OK

title

title

Rejected

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From Fully Automated Station to User Intervention

Steady state Checking data

Visual inspection Analysis room

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Point Selection and New Large Data Set Paradigm

• Point selection from the pool points

• For best use of time feature/surface optimization is recommended

• A 50 x 50 cm tile can replaces many surface points

• Features and points grouped together can be covered more effectively

• With fast joint changes a full area can covered

Robot Movement & wait times

Robot/PLC-Communication

Image Acqusition

2-3.5 sec*

0.1 sec*

0.5-1.5 sec*

*Per tile

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Point Selection and New Large Data Set Paradigm

• Transform from critical points only to our added value capabilities surface

colormap, xs, edge line, etc

• Add multiple programs to help support various process life cycle stages

• Add Special studies to even increase system value during launch and breaks

Subroutine 1

Subroutine 2

Subroutine 3

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Cycle time limited Measurements + Special Studies

• 2 operating modes for special studies:

• Line down time or ramp-up and initial launch periods

• Running during breaks or between shifts

• Examples for special studies:

• Body to closure assembly (Functional & Flush and gap areas)

• Interior / instrument panel assembly study

• Fuel outlet assembly area

• Engine assembly area

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Back lights Assembly Area Detailed Study – Detailed AnalysisSpecial study alignment based on assembly features Cross section 2D analysis on back light area

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Additional Analysis as needed

Special Round Edge line Measurement for

F&G analysis

Changing Colormap settings to support

tighter tolerances

Measuring all critical features

and points in the area

Matching Surface Point for F&G analysis

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Patented VSPC for Problem Solving and Process Stability Analysis

• Comparisons

• Averages and ranges

• Statistics / Trend charts

• Finding closest to median

• Virtual Master Part

• Comparing Groups of parts

• Generating unified result

• Generating virtual results from statistics

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“Image of the day” reporting

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Patented “Video-of-the-day” – Split Screen on different areas

• Patent Pending

• Full shift in 60 sec clip

• Part, Trend, +summary statistics

visualization

Roadmap:

• 360 SIMS DataServer enabled

• Automated generation

• Distribution to user / mobile devices

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Patented “Video-of-the-day” – Split Screen on different areas

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In Future – more actionable data into the video report

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Small and Large Data set

Cell Monitoring

3rd Party Integration

QDAS/SPC

Mobile Reports Generation

Video of the day generation

Search results

More Ways for Using and Accessing the Metrology DATA

Metrology

Database

Application

Server

• Server provides access to users and application to all managed data

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The Data Challenges

We create a lot of data and needs to be:

• Stored

• Distributed

• Managed

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Data Management and Storage - Recommended

Cell Data Server (all measurement results)

• 6 months of data advised

• Older then that to be backed-up on archived storage in IT room

Network File Storage (.cto, PDF, Pics, Videos others)

• Very short term saving of full projects (GBs per measurement)

• Naming convention based on customer wishes

• Unlimited storage but requires periodical maintenance

Customer SPC / IT systems (f.i., csv, dmo, DFQ, quirl, etc)

• Agreed formats saved for automatic processing by customer system

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~50 Mgb per part

700 parts/day

35 Ggb per day

Saved time, 6 months ≈ 6.4 Tb

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Casting Measuring Cell

Our Vision: Integrated Metrology Solutions Leveraging 360 SIMS,

MMS and Q-DAS Platforms for Actionable Workflows

F&G Measuring Cell

Assembly Worker

Quality Analyst

Closure Measuring Cell

MMS Application

Server

Metrology

Database

BiW Measuring Cell

• Data from all measurement systems is collected and managed

Connecting various

metrology systems

in the factory with

the different users

for quality data

Thank you !