Quality Manufacturing Today Magazine September 2008

8/14/2019 Quality Manufacturing Today Magazine September 2008

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www.metris.com

september 2008

www.qmtmag.com

LC60D - Revolutionizing CMM Laser Scanning
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PRECISION IN

MOTION

MH3D

Reflex

MH3D

Contact

Vision

MH3D

DCC M

Visio

500MH3D

DCC I

TESA Technology UK Ltd

Metrology House, Halesfield 13, Telford, Shropshire, TF7 4PL

Tel: +44(0)1952 681349 Fax: +44(0)1952 681391 [email protected] www.tesabs.ch
mailto:[email protected]:[email protected]:[email protected]://www.tesabs.ch/http://www.tesabs.ch/mailto:[email protected]


3/403QMT September 08 www.qmtmag.com

CONTENTS

September 2008News and comment 4

Blisks & integrated measurement 8A complex new product development, Blisks, for the huge

JSF programme, presents an unprecedented challenge

for Rolls-Royce on how to integrate CMM measurement

technologies into new manufacturing processes.

Laser radar in its sights 14Janicki Industries utilizes laser radar measurement tech-

nology to develop innovative composite tooling for

large-scale lightweight prototype aircraft.

Focus on NIST 18The US National Institute of Standards and Technology

(NIST) plays a significant role in underpinning US eco-nomic and technological development. By Thomas

Shattuck

Wenzel - the first 40 years 2140 Years of Wenzel Precision are being celebrated this

year. Strategic acquisitions look set to play a major role

in the companys drive for dynamic growth.

CMMs 23

Surface and form measurement 25

Micro & nanometrology 26

Global approach to QMS 28 World leading industrial fasteners company, Anixter

Fasteners, has standardised its global quality manage-

ment system on a single platform solution.

Lift off for Burcas 30A supply chain development programme based on a six

sigma and Lean approach leads to a 1m aerospacecontract for Burcas.

SPC & data collection 33

Food inspection gets better 34New inspection X-ray technology developed by European

researchers is helping to ensure that the only thing in

peoples dinners is the food itself.

Materials testing 36

Inspex 2008 focuses on quality 37Inspex 2008 is the event for the UKs quality manufactur-ing professionals to check out the latest in test, measure-

ment and inspection technologies.

Editor: Brendan CoyneEmail: [email protected]: 00 44 1580 715152

Media Director: Dawn WisbeyEmail: [email protected]: 00 44 208 2897011Mob: 0044 797 4640371

Website: www.qmtmag.com

Quality Manufacturing Today , pub-lished eight times a year, is a print andon-line magazine for the quality,measurement and test industry pro-moting improvements in manufactur-ing processes and products throughquality control and quality manage-ment - from shopfloor to line andenterprise management.

Quality Manufacturing Today is pub-lished by Cranbrook Media Ltd.Registered company No. 06048241Registered office: The Coach House,Angley Road, Cranbrook, Kent,

TN17 2LE, UK.

Printers: Premier Press, Southend Cranbrook Media Ltd.

Front cover:Metris

www.metris.com

Product and feature articleenquiriesLog on to www.qmtmag.com fordirect links to companies andproducts featured in this issue.

www.qmtmag.com
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Applus+ acquires lead-ing US NDT groupApplus+, one of the largestcertification companies in theworld, has acquired the JanXIntegrity Group (JanX), a US

market leader in non-destruc-tive testing and inspection(NDTI). JanX will be integratedin Applus RTD, the largestNDTI provider worldwide,strengthening its strategic posi-tion and increasing its serviceoffering in the US. This opera-tion will allow Applus+ toreach revenues of $100M inthe USA.

This is the second acquisi-tion since The Carlyle Group,and a consortium led by CaixaCatalunya, took over themajority of the company lastNovember. Applus+ started2008 by buying MBI, a UKleader in NDT.

www.applus.com

Technology acquisitionsfor WenzelGlobal precision CMM com-pany, Wenzel, has announcedtwo new acquisitions -

Knotenpunkt GmbH andVolumetrik GmbH. Volumetrikis a X-ray computer tomogra-phy company andKnotenpunkt is a manufactur-er of reverse engineering soft-ware, technology and CNCcontrollers - for more details,see feature on Wenzel onpage 21 of this issue.

www.wenzel-group.cmm

New Bowers trainingand distribution facilityThe Bowers Metrology Grouphas recently opened a newdistribution and training facilityin Shanghai, China. The2,500 square metre facility willserve as the Chinese distribu-tion hub for the companys

Free 5-axis measure-ment seminars

World leading metrologycompanies Renishaw, Metris,Mitutoyo and Wenzel, andCAD/CAM developerDelcam, are holding a seriesof free half-day UK seminarsin Autumn 2008 coveringRenishaw's Renscan5 five-axismeasurement technology,including the award-winningREVO measuring head. Eachof the events will cover the

operation and applicationsfor the new system, compati-ble software packages, itssuitability as a retrofit option,but fundamentally the hugethroughput benefits that thenew technology can bring tousers of co-ordinate measur-ing machines (CMMs).

The first event will be heldat Metris near Derby on 9thSeptember, followed by an11th September event at

Wenzel in Gloucester andthen at Mitutoyo's Andoveroffices on September 17th.During November there willbe events at Renishaw'sWotton-under-Edge head-quarters on Tuesday 4th, atDelcam's Birmingham head-quarters on Tuesday 18th,and concluding with a north-ern event at Mitutoyo inHalifax on Thursday 20thNovember.

To register for the seminars,

please use the on-line booking

form at:

www.renishaw.info/roadshow,or contact Katie Hibbitt on

01453 524414.

Editors commentWith all the uncertainty overthe economy, caused by thebanks and financial sectorscollective irresponsibility oversub prime lending on a

gigantic scale, its great tohear some positive news. Imean Team GBs medal haulin the Olympics. The best forover a hundred years andfourth in the medal tablebehind China, USA andRussia, but ahead ofGermany, Japan, France andItaly..

Why did it take so long?Perhaps the difference thistime was that the UK thought

strategically, put in invest-ment and promoted a cultureof improvement and selfbelief - all things which canbe directly translated into thecompetitive manufacturingarena. Surely, there are les-sons to be learned here forany nation seeking toimprove its manufacturingposition - or indeed, anyother endeavour.

One of the keys has to bean ability to think and seestrategically and to recognisewhat is actually happeningon the ground.

Clearly, when it comes tothe sub prime fiasco, therewas either an unwillingnessor, perhaps worse, an inabili-

ty to think and see the reality.I would like to think that

those who are familiar withquality assurance and qualitycontrol culture, such as read-ers of QMT, would havemade a better job of it all -

after all, we have the culture,tools, technologies and tech-niques to envision, map,monitor, control and improvesystems! Surely, some sort ofquality audit would have pro-duced plenty of correctiveactions in the sub primeprocess? Or is it the casethat the financial sector hadplenty of quality systems,which complied with theappropriate standards butdidnt deal with the funda-

mentals i.e.an efficient sys-tem producing what the mar-ket apparently wanted, con-sistently, reliably, but whichwas poison for the world?

Brendan Coyne

NEWS

www.qmtmag.com QMT September 084

NEWS

Corus Northern Engineering

Services (CNES) has manufac-

tured a 3,000 tonne hydraulic

test rig for Oil States Industries

(UK) Ltd based in Aberdeen.

The press is a complete tension

compression test rig, which willbe delivered to an Oil States

customer in China, Tianjin Pipe

Corporation (TPCO), who will

use it to ensure its seamless

steel pipe is fit-for-purpose.

The press measures 13m(L) x

2m (H) x 2.5m (W) and weighs

just over 70 tonnes.

Oil States Industries is a

global provider of deepwater

production products and sub-

sea pipelines for the offshore

and onshore oil and gasindustries. The test laboratories

at Aberdeen are accredited to

UKAS ISO 17025 and have

their own in-house designed

2,000 tonne hydraulic press.

www.corusnes.comContinued on page 5

IN BRIEF

CNES builds 3,000 tonne tension compression rig
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bore gauging products thatare manufactured in Bowershi-tech manufacturing plant inBradford, West Yorkshire.With exports currentlyaccounting for 79% of compa-ny turnover, Bowers plan to

expand the new facility furtherin the near future, with BowersShanghai acting as a distribu-tion base for the companysnew range of Eseway PremiumRockwell Hardness Testers.

www.bowers.co.uk

Automated Precisionand Metris jointdistributor agreementAutomated Precision, Inc. and

Metris have announced theformation of a joint distributoragreement. API will become anon-exclusive distributor forthe Metris MCA ArticulatedArm and the ModelMakerhand held scanner. At thesame time Metris will becomea non-exclusive distributor ofthe APIs Tracker3 LaserTracker.

www.metris.comwww.apisensor.com

Hexagon Germanmachine tool probeacquisitionHexagon has acquired all out-standing shares in m&hGroup. The Group consists ofthe three German companiesm&h Inprocess MesstechnikGmbH, m&h InprocessInternational Trading GmbHand m&h Inspect GmbH.

m&h is a leading developer,manufacturer and distributorof machine tool probes includ-ing related software and serv-ices

www.mh-inprocess.com

Hexagon to acquire theChinese companyHexagon has entered into anagreement to acquire Chinesecompany, Serein Metrology(Shenzhen) Co. SereinMetrology develops and pro-duces a wide range ofadvanced precision measuringinstruments in the micro areaof the measurement technolo-gies market. The companyprovides high quality products,

NEWS

QMT September 08

8-13 September 2008

IMTS08 International

Manufacturing Technology

Show

Chicago, Illinois, USA

www.imts.com

16-18 September 2008

NDT 2008

The 47th Annual Conference

of The British Institute of Non-

Destructive Testing

Shrigley Hall Hotel, near

Macclesfield, Cheshire, UK

www.bindt.org

24 - 25th September 2008

MEDTEC Ireland Conference

Galway, Irelandwww.medtecireland.com

www.inspex.co.uk/

October 7 - 8th 2008

Northern Manufacturing exhi-

bition

Sheffield, UK

www.industry.co.uk

October 21 -22nd 2008

TCT exhibition &

MM Live Exhibition

Ricoh Arena, Coventry

www.time-compression.com

www.micromanu.com

October 27 - 30, 2008

4th Annual European Lean, Six

Sigma & Process Improvement

Summit

Hotel Okura, Amsterdam, TheNetherlands

www.europeanleansixsigma.com

November 5-6th 2008

Manufacturing Technology

exhibition

Dublin, Ireland

www.industry.co.uk

November 18-20th 2008

AeroTest America

Fort Worth, Texas, USA

www.aerotestamerica.com

3 -6th December 2008

Euromold 2008 exhibition

Exhibition Fair Ground,

Frankfurt / Main, Germany

www.euromold.com

EVENTS

The Measure of Success

Measure everything

as easy as a cube.FAROs portable 3D measurement

systems make measuring com-

plex objects easy. This includes

alignment, calibration, inspection,

reverse engineering, and as built

documentation with a measuring

range between 0 and 70m and

accuracies up to 5 microns.

More information atwww.faro-products.com

or 00 800 3276 7253FARO,THE MEASURE OFSUCCESSare aregisteredtrademarksand trademarksof FARO Technologies Inc.

2008 FARO Europe GmbH & Co. KG. All Rights Reserved.
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solutions and services to theautomotive industry, aerospaceand defence industry, engi-neering industry, die andmould industry, electronics, ITand medical industry.

Serein Metrology is based in

Shenzhen, China, and todayemploys 98 people. The com-pany had a turnover ofapproximately 4 MUSD in2007 and is expected to growat a double digit rate in theyears to come

www.serein.com.cn

US office for NanoSightNanoSight, the nanoparticlecharacterization company, hasopened offices in the USA at

Morganville, New Jersey, toprovide local sales, applica-tions and service support totheir growing family of users.

NanoSight will share facili-ties with the complementaryUS nanotechnology company,XiGo Nanotools, a companyapplying NMR technology fornanoparticle characterization.

www.nanosight.co.uk

Food testing lab forBeijingIntertek, international providerof quality and safety services,has opened a new food testinglaboratory in the southwestarea of Beijing, China to offer

an array of services to manu-facturers, distributors, andretailers who produce, import,buy and sell food products inBeijing and Northern China.

www.intertek.com

European workshopmaps metrologyprioritiesFollowing a roadmappingworkshop held last May atLoughborough, and co-spon-sored by CEMMNT (Centre ofExcellence in Metrology andNano Technologies), a reporthas been published highlight-ing the trends, challenges andopportunities facing measure-ment and characterisation. Theworkshop comprised of adiverse group of experts gath-ered from across Europe withinterests in measurement and

characterisation and design ofmicro and nano technologybased products and systems.

http://cemmnt.co.uk

UK vehicle productionrises in JulyCar output rose by 1% in July(to 131,079 units) and is posi-tive for the year to date, saidPaul Everitt, SMMT chief execu-tive. The Qashqai+2, whichwas recently launched at theBritish International MotorShow, has gone into produc-

tion and it is expected that theSunderland plant will producearound 270,000 of both ver-sions of Qashqai in 2008 andan estimated 450,000 vehicleswill come off the line in total.

Commercial vehicle produc-tion saw exceptional growth of50% in July 2008 (at 20,997units),

source: SMMTwww.smmt.co.uk

NEWS


Metromeet launchesthe call for papers for2009

Metromeet, the 5th edition of

the International Conferenceon Industrial Dimensional

Metrology, will take place on

26 and 27 March 2009 at the

Euskalduna Conference Centre

in Bilbao, Spain. Metromeet

has launched a call for papers

to professionals and industry

experts to share their experi-

ences and knowledge.

In the next Metromeet edition,

organized by Innovalia

Association, new solutions for

metrological industry, roboticsfor metrology, optical measur-

ing systems, calibration sys-

tems for the measurement of

metal and the new hybrid sys-

tem, amongst others, will be

shown.

The deadline for submitting

papers ends on September

18th.

www.metromeet.org

ECONOMIC

INDICATORS

CALL FOR PAPERS
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The Joint Strike Fighter, JSF, next generationtactical strike aircraft is a stealth, multi-roleaircraft. Based on a single, common design

with three variants, including a Short Take Off &

Vertical Landing (STOVL) option, the end userswill be the US Marine Corp, Navy and Airforcetogether with partner nations forces, such as theUK, and Canada. In 2001, the US Department ofDefense selected the Lockheed Martin X-35 con-cept plane, which has now become the F-35Lightning II Joint Strike Fighter. With an estimat-

ed programme requirement of 3,500 aircraft, theUS government funded budget will be in theregion of $298bn spread over 30 to 40 years.

Aerospace manufacturer Rolls-Royce will con-

tribute to the programme by manufacturing sever-al key components, including highly complexBlisks.

For conventional take off, there are two engine

derivatives available. The F-135 engine is a pure-ly Pratt & Whitney engine in which Rolls-Roycehave no stake. The F-136 engine is a joint collab-oration between General Electric and Rolls-Royce, with Rolls-Royce responsible for the man-ufacture and supply of several key modules, oneof which is the full fan system at the front end of

8 QMT September 08www.qmtmag.com

Blisks & integrated measurement

In the space of 11 years up to 2017, we

will go from producing a Blisk every three

months to one Blisk every eight hours.

DIMENSIONAL METROLOGY

A complex new product development, Blisks, for the huge JSF programme,

presents an unprecedented challenge for Rolls-Royce on how to integrate

CMM measurement technologies into new manufacturing processes.

By Brendan Coyne.

F-35 Lightning II
http://www.qmtmag.com/http://www.qmtmag.com/


9/40

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10/40www.qmtmag.com

the power plant. The fan system consists of threelarge diameter Blisks, which will initially be man-ufactured in existing Rolls-Royce plants in the UK.

For those customers who wish to have STOVLcapability, the Rolls-Royce Liftsystem is the onlyoption. The Liftsystem comprises of four key com-ponents, one of which is the shaft driven liftfan.The liftfan contains a further two large diameterBlisks. The Liftsystem can produce a thrust of inexcess of 40,000lbs. Compare this to the Harrier,which in combat mode in conventional flight onlyproduces about 30,000 lbs of thrust.

What does this mean in terms of a Blisk NewProduct Introduction (NPI) programme within thecompany? The first thing Rolls-Royce did was to

establish a Blisk pre-production facility, dedicatedto manufacturing a range of new Blisks.Introducing many new manufacturing technolo-gies, many of which had never before beenapplied on Blisks, the purpose of the pre-produc-tion facility is to finalise the manufacturing devel-

opment and to seal the method of manufacture oneach of the Blisk components and, then, to gradual-ly increase the facilitys output to its full capacity.

Dean Whiteside is responsible for measurementprocesses in Rolls-Royces UK Blisk manufactur-ing plants. Currently, Dean is probably the leadprotagonist within the organisation for the need todevelop 5 axis scanning technology within themeasurement process for more complex geome-try, such as aerofoils and free form shapes.

One of the first challenges he faced was theestablishment of the measurement cells at

Hucknall, a Blisk pre-production facility, whichhad received a capital investment of approaching1.3m in measurement systems alone. At thestart of the programme, we had to demonstrateour capability, in a small demonstration area, toproduce one Blisk every three months. Now,weve migrated to pre-production and arerequired to demonstrate that we can produce at arate of one Blisk per week. When we migratefrom pre- production and go to full factory pro-duction, (in a facility yet to be built) the rate has toincrease to one Blisk per 8-hour shift at peak vol-

10 QMT September 08

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ume. So in the space of 11 years up to 2017, wewill go from producing a Blisk every three monthsto one Blisk every eight hours. Clearly, we have amajor challenge ahead of us in ramping up tothese numbers.

This NPI programme is unprecedented within

Rolls-Royce. Explains Dean Whiteside, We areintroducing up to six new products, whilst simul-taneously introducing new manufacturingprocesses to produce these parts. We have verydemanding customers in the Liftsystem and F-136projects who are understandably pushing manu-facturing to make sure they meet their criticalmilestones.

Measurement challengeBlisk manufacture involves extremely complexprocesses. The majority of these processes arenovel and, as a result, there has been a significantdemand on the measurement processes to supportand establish the capability of these processes.Measurement plays a critical role in this plant, notonly in product conformance at the end of the linebut also to assist in manufacturing development.Right from the outset, it was clear to me that

measurement, within a concurrent engineeringenvironment, would play a key role in ensuringthe successful delivery of JSF Blisks. To meet thesetight schedules we had to utilise the capabilities ofoff-line programming of coordinate measuringmachines (CMMs).

For off-line programming, we required function-

ality which would allow us to produce a verylarge number of CMM part programs over a veryshort period of time for the six variants of Blisk.

Adding to the challenge was the absence of aphysical part to program around on the CMM. Tomeet the tight customer milestones, we had to

minimise the time the parts spent on the CMMs.We couldnt wait for the parts to arrive at theCMM and then begin writing the CMM program.This would add a significant lead-time onto themanufacture of the first off Blisks, which was com-pletely unacceptable.

When the actual part arrives at the CMM, Iallowed a day per CMM program to test and proveout the off-line written part program on the actualpart. For this to work, we required the off-line pro-gramming software to be capable of producingand simulating 90-95% of the required functional-

ity with minimal time required for subsequentediting. However, we soon found that in realitythe level of capability required fell some wayshort. For various reasons, the off-line program-ming systems were only capable of delivering 40-50% of the required functionality. (These com-ments are not aimed at saying a particular CMMsoftware does not deliver what we require. Wevecome to the conclusion within Rolls-Royce thatthere is no one single offline solution that providesall our requirements in terms of CMM program-ming capability).

The primary reason for this is that the Bliskcomponent is one of the most complex parts thatRolls-Royce manufactures featuring a combina-tion of prismatic and freeform geometry. Themore complex functionality required to measureBlisks was not supported by the off-line systems.Also, several items of ancillary equipment that arekey to the measurement process, such as rotarytables, were not integrated, at that point, withinthe virtual CMM environment. A true measure-ment process couldnt be fully simulated prior tothe part actually arriving at the CMM. This meantthe measurement team still had to write a large

proportion of the CMM programs on the physicalpart when it arrived at the CMM.

Product Life Cycle ManagementAdding to the challenge, the measurementprocess has to operate within the context of aProduct Life Cycle Management (PLM) rolloutbeing piloted by JSF Blisk manufacturing withinRolls-Royce. PLM works if all the data relation-ships are truly integrated. For example, in theBlisk programme, Design Engineering, based inBristol are the authority for geometry of the prod-

uct. They interface directly with the componentowners, who themselves are the individualsresponsible for the product within the manufactur-ing environment. The component owners caninterface directly, (exchange geometry in terms ofmaster models, stage models etc.) with the variousmachining process owners via UGS TeamCentre




13/40

within the manufacturing environment. Theprocess owners are the individuals responsible forthe various manufacturing processes used to man-ufacture Blisks. The ability to interface betweenDesign Engineering, Component Owners andProcess Owners provides full geometry associativ-ity. If there are any design changes driven byDesign Engineering an automatic cascade of thesechanges and the relevant associativity is appliedto the manufacturing processes via theTeamCentre environment.

PLM does support concurrent engineering. Butwhere does measurement fit in? It doesnt cur-rently, says Dean Whiteside. (As far as we areaware), there is no PLM solution that truly inte-grates the measurement process within the PLMenvironment as it does with CAM. The measure-

ment process was isolated from thePLM/TeamCentre environment. It was and still is astand alone process with no direct interfacingwith the PLM system. This can cause major prob-lems, particularly for the measurement process ifgeometry changes are not communicated to thewhole integrated project team. Rolls-Royce usesUniGraphics Siemens PLM and we are in the veryearly stages of starting to understand how tomigrate the measurement process into UGS PLM.But progress is slow and there is still a very longway to go!

Today, measurement is an integral element ofour manufacturing systems. We need to ensurethat latest measurement capabilities are built intofuture PLM developments. Equally, we need torecognise that since original implementation,technologies have advanced. Alternative forms ofsensor probing devices need to be investigatedsuch as on-machine, and 5-axis CMM scanning,that potentially offer a more cost effective andintegrated solution. These developments clearlyneed to be captured in the PLM environment.G

E-mail: [email protected]

13QMT September 08 www.qmtmag.com

mailto:[email protected]://www.qmtmag.com/http://www.aberlink.co.uk/http://www.qmtmag.com/mailto:[email protected]


14/40

Janicki Industries, based in Sedro-Woolley,Washington, USA, produces high-precisionadvanced composite tools and excels at

designing and fabricating large complex compos-ite tooling. The companys (pole) models, testequipment and full-size metallic and composite

structures are typically used as prototypes foraerodynamic property testing, radar testing or forany other customer requirement. Today, toolingexpertise developed at Janicki serves the majorityof international aircraft OEMs as well as manufac-turers of boats, motor homes, buses and mono-rails. The company has a growing involvement intooling development for composite wind turbine

blades, and occasionally participates in specialprojects, such as prototyping speedy racing yachtsthat compete in the renowned Americas Cup.

When developing new tooling concepts forlarge prototype structures, Janicki faces short turn-around times and high-precision requirements. Asa result, the companys metrology specialists arefully occupied with systematic quality verificationof structural assemblies being developed. Tomeet the growing demand for tighter timing dead-lines in developing large aircraft fuselage sections,our metrology team opted for three Metris Laser

Radar systems to validate OEMs geometricrequirements, John Janicki, vice president of Janicki Industries, stated. Deciding factors werethat the laser radars operate without spherically-mounted retro-reflectors (SMRs) or remotedevices, and reliably deal with composite surfacesand sharp scanning angles. In automatic mode,


Laser radar in its sights

LASER RADAR MEASUREMENT

Janicki Industries utilizes laser radar measurement technology to develop

innovative composite tooling for large-scale lightweight prototype aircraft parts

Metris Laser Radar


15/40

Total qualitycontrol solutionswhere you needus most

everywhere!Coordinate Measuring Machines Vision Measuring Machines

Small Tool Instruments

Software

Digital Scale and DROTest Equipment and Hardness Testers

Optical MeasurementForm Measurement Sensor Systems

Support Services and Training

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other remote devices. Compared to laser trackerequipment, where one person operates the track-er and the other one holds the device, the MetrisLaser Radar system can be operated by a singleperson. This eliminates a second operator, who

would otherwise need to physically access themany measurement locations on the concave sur-faces of the fuselage structure. Overall, when con-sidering non-contact laser scanning in automaticmode, we succeeded in increasing geometry verifi-cation productivity by a factor of 5, stated MichaelBatchelor. At the same time, the accuracy of thelaser radar meets or exceeds our customers preci-sion requirements. Besides high accuracy, the laserradar guarantees high measurement repeatability,which allows us to confidently perform direct point-to-point measurements.

Large-scale accuracy is a real challenge, espe-cially since Janicki becomes increasingly involvedin tooling projects for very large composite parts.Over the years, the companys growing internalmetrology group gained top metrology expertiseand has innovate measurement equipment inhouse, including the three laser radar systemsfrom Metris. The combination of specializedmetrology expertise and market leading equip-ment speed up geometry verification to help meettighter tooling project deadlines, and offers greatopportunity to explore new business throughmetrology outsourcing projects.

Originally, Janicki focused on developing CNCmilling machines that convert CAD files intoplugs, patterns, molds and prototypes parts forlarge items. As an innovation company that sys-tematically searches for new emerging technolo-gies, Janicki recognizes the potential of utilizingMetris Laser Radar as part of large gantry mount-ed drilling machines. In this case, the laser radarwould provide independent adaptive positioningcontrol of the drilling head, which in itself woulddrastically reduce the cost of the positioning over-head of these massive machines. The enabling

metrology technology of the Metris Laser Radarwould enable Janicki to design and build costeffective automated milling equipment to accom-modate even larger composite parts to produce.G

www.metris.com

17QMT September 08 www.qmtmag.com

LASER RADAR MEASUREMENT
http://www.metris.com/http://www.qmtmag.com/http://www.measurement-solutions.co.uk/http://www.qmtmag.com/http://www.metris.com/


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The National Institute of Standard andTechnology, NIST, is a non-regulatoryagency under the United States Department

of Commerce that aims to improve the standardsof measurement to provide economic stabilityand technological development. NIST receivedapproximately 755.9 million dollars this past yearto fund its various projects and is currently seek-ing a 7.4 percent increase for the year 2009,though only a 1.4 percent increase has beenapproved by the US Congress. With the budget

significant returns have been made. For everydollar spent on metrology, the Institute calculatesa return of three dollars and thirty cents through-out industry as a whole.

Within NIST, the Dimensional MetrologyProgram (DMP) aims to improve American com-petitiveness by providing metrological standards

and tools for industries with a significant U.S.presence. DMP achieves their goals in manyways, most notably through coordinate-measuringmachines (CMM) - particularly transportable sys-

tems such as laser interferometers and laser track-ers.

The large scale metrology industry is rapidlymoving to optical measurement systems. Unlikelarge fixed placement CMMs, these new systemscan be easily transported to different measure-


Focus on NIST

For every dollar spent on metrology,

the Institute calculates a return of three

dollars and thirty cents throughout

industry as a whole.

NIST

The US National Institute of Standards and Technology (NIST) plays a

significant role in underpinning US economic and technological

development. By Thomas Shattuck

NIST "M Cubed" molecularmeasuring machine


19/40

Let us show you how to get more from your CMM or other Metrology instrument

whatever the make, with an upgrade to Calypso software from Zeiss.

Interested? Contact us now to arrange a demonstration.

Software for all...

...with CALYPSO

Carl Zeiss Ltd.

Division of Metrology

2 Hadrians Way

Glebe Farm Industrial Estate

Rugby, Warwickshire, CV21 1ST

Phone: 01788 821770 Fax: 01788 821755

Email: [email protected]

Website: www.zeiss.co.uk/metrologyWe make it visible
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20/40www.qmtmag.com

ment sites, have significantly lower capital equip-ment costs, and allow factory floor space to berapidly reconfigured.

New optical technologies that provide absolutedistance measurement (ADM) capability eliminatethe need to transport retroreflectors from the sys-tem to the workpiece and the associated problems

of beam breakage. For that reason, measurementtechnology using ADMs has exploded in recentyears and numerous firms are developing newproducts and measurement services. The UnitedStates claims to lead the world in this technology,particularly in the development of ADM lasertrackers.

The DMP is supporting this crucial technologythrough development of a high accuracy 60 metertest range that can calibrate ADM ranging sys-tems. Direct assessment of the errors in these(often highly proprietary) ADM systems helpsmanufacturers of this technology to improve theaccuracy of their equipment and gives users con-fidence in the measurements. Using NISTs exist-ing tape calibration facility, augmented with anewly developed high accuracy long range inter-ferometer system, represents a unique US nation-al resource. Current test range calibration uncer-tainties are U(k = 2) = 2 m + 3 10-7 L for coop-erative targets (specially made to be ADM friend-ly) and U(k = 2) = 10 m + 1 10-6 L for nonco-operative targets .

Along with improving metrological tools, theDMP is also interested in entrenching US techni-

cal standards in new fields. They have succeededin several key areas including measurementuncertainty, traceability and standards forCartesian CMMs. Furthermore, the DMP hopes todevelop standards for laser scanning sensorsincreasingly used with various types of CMMs.This will allow for the accurate measurement of

objects in the


21/40


22/40www.qmtmag.com

range of Knotenpunkt covers the whole area ofdigitization and processing of point clouds andthe complex field of reverse engineering. Its soft-ware includes PointMaster for reverse engineer-ing and measurement. Integrating PointMasterinto Wenzels DesCAD design software provides

all the functions - from digitization of a model tomilling - with just one tool. Supporting this area isShapetracer, which records surfaces and contoursof physical parts.

On the software development side, Wenzel hasannounced Metrosoft QUARTIS, the first measur-ing software based on the innovative MicrosoftOffice Fluent user interface. The new interface isvery clearly arranged, flexible and goal-oriented.The result is a highly innovative operation con-cept, which enables all users easy and fast access.Deliveries of QUARTIS will start in January 2009,

say Wenzel.Yet another strategic technology acquisition is

computer tomography company, VolumetrikGmbH. Announced in July, this acquisition takesWenzel into a fast developing x-ray CT technolo-gy with strong growth potential. Using computertomography machines it's possible to make con-tactless 3D-measurements of inner and outerstructures in a range of materials and in manydiverse applications.

"By integrating our many years of experienceand competence in the field of computer tomog-

raphy into the WENZEL Group we have the bestopportunity to compete in the market for contact-less volume measurement with our innovativetechnology", says Dr. Martin Simon, managingdirector of Volumetrik.

UK celebration CMMTo celebrate Wenzels 40 years, Wenzel UK hasannounced the XO87 40th Anniversary Editionbridge type coordinate measuring machine.Coming in at a remarkably competitive price of34,040 +VAT, the package includes a full CNCsystem, all granite axes design with a measuringstroke of X-800, Z-700 & Y-1000mm. Volumetricuncertainty is 2.5+L/300m. The packageincludes a Renishaw PH10/TP200 Probe System,Metrosoft measurement software, new Fujitsu PCwith Flat screen & printer plus delivery Installation

& 12 months warranty together with full trainingfor 4 people. Lastly, Wenzel UK are throwing in afree Renishaw SCR200 Toolchanger.

Andy Woodward, managing director of WenzelUK comments, This special edition of the XOCMM will enable our UK customers to takeadvantage of a medium sized CMM at a very spe-cial anniversary price, coupled with what manycustomers in this market segment require, imme-diate delivery.G

www.wenzel-cmm.co.uk

22 QMT September 08

COMPANY PROFILE
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PRODUCTS

www.qmtmag.comQMT September 08 23

CMMs

Revolutionary prototypetooling methodTo quickly and cost-efficiently

bring new products to themarket, the automotive andother industries require rapidways of building stable and

accurate prototype tooling. Anovel approach from Metronorand Tetrafix sets new stan-dards in terms of tool align-ment speed and accuracy,combined with mechanical sta-bility, while using only a few

standard components to createa wide variety of geometries.

The required tool geometry

can be built in minutes using apatented concept with struc-tures made up of modular car-bon fibre tubes and adjustable

joints. The Tetrafix structurepermits free movement of thedetail adapter in space, mak-ing the positioning processquick and efficient, and thestructure is simply locked inplace using a hex key once thecorrect position is achieved.

Thereafter, the LED cluster is

removed and the tooling detailis clamped in its place. Oncelocked, the entire structure isextremely stable and fully ableto withstand the shop floor.

To align tooling details like

clamping devices, net blocks

and indexing pins to within 0.1mm accuracy, a special tetra-hedron cluster with a numberof Light Emitting Diodes (LEDs)are clamped onto the tooldetail adapter. These LEDs are

monitored by a MetronorDUO portable coordinatemeasurement system, provid-ing continuous feedback onposition until the detail is inthe required position.

www.metronor.com

Tube measurementsolutionFARO, provider of portable 3Dmeasurement devices andTeZet, the Swiss-based tubemeasurement software special-ist, have entered into a newEuropean technology andmarketing agreement for tubemeasurement. Under the

agreement, TeZets tube spe-cialised software solutionTeZetCAD, will be integratedinto portable devices for 3Dmeasurement - the FAROScanArm and FaroArm.

The innovative element ofthe agreement is the ability tomeasure freeform bent tubeswith the FARO Laser ScanArmso that tube benders can actu-ally bend tubes by extractingthem graphically from CAD
http://www.qmtmag.com/http://www.metronor.com/http://www.crane-electronics.com/http://www.metronor.com/http://www.qmtmag.com/


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drawings.TeZet offers a soft-ware module for FAROScanArms that allows automat-ic calculation of tube data dur-ing the scanning procedure.

The user no longer needs touse the complex and lengthy

method of converting millionsof points in order to extract thetube coordinate and bendingdata necessary for masterpieceinspection and comparison

within the production proce-dure.

www.faro.com

Measurement versatilityLatest addition to the Tesavision system range is theVisio 500. Employing a mov-

ing bridge mounted on air-bearings, the Tesa Visio 500 isa high speed, high accuracymulti sensor system

Measuring table (X,Y) is 400x 500mm with a Z axis up to300mm.

Visio 500 can be equippedwith a CCD camera, aTesaStar probe head or atouch-trigger probe coupledwith a PC video camera.

Able to meet challenging

measurement features on acomponent, the Teas Visio 500Universal version can be fittedwith any optional components,such as black and white CCDcamera, red or white light orTTL laser scanning sensors.

Different systems for clamp-

ing measured componentscan be mounted on eachmodel, including a fourth axisrotary device for measuringcylindrical parts. Measurementsoftware is PC-DMIS.

www.tesabs.ch

The Zenith of CMMtechnology?

Aberlink claim the industrysbest performance to cost ratiofor its new Zenith Too range oflarge capacity CMMs. The newseries of CMM ] consists of 10machines with XYZ capacitiesranging from 1000x1000x600

to 1000x3000x800mm.The Zenith Too range is an

all aluminium construction withadvanced drive design andraised guide-ways .This

ensures extremely low inertiacharacteristics for high speed

operation. In addition, itsmeasuring structure is com-pletely independent of themachines granite surfacetable. The Zenith Toos lowthermal mass and robust char-acteristics enable accurate

measurement of large compo-nents both on the shopfloorand in a QC controlled envi-ronment.

www.aberlink.co.uk

CMMs

QMT September 0824 www.qmtmag.com

Front cover story

Metris LC60D laserscanner revolution-izes digital inspection

The Metris LC60D next-gen-

eration digital 3D line scan-ner more than triples todays

common scan rates. LC60Dstrengthens and acceleratesthe digital inspection processby making the digitizingprocess faster and morestraightforward.

A major leap forward com-pared to its LC50 predeces-sor, the LC60D line scannerdelivers a significantincrease in productivity,which is achieved by speed-ing up the image acquisition

frame rate from 25 to 75Hertz. In combination with

15% wider laser stripe and17% higher point resolution,the scan speed of the LC60Dreaches 75,000 non-interpo-lated points per second

The massive amount ofmeasurement points acquiredat 15 micron accuracy radi-cally increases the surfacearea the scanner is able tocapture and process. As aresult, LC60D operators can

complete scanning jobs up to

3 times faster. This allowsmanufacturers to drasticallycompress the inspection cycletime for freeform parts, orboost the number of featuresthat can be scanned in the

same time frame.The digitizing capabilities

of the LC60D scanner areequally beneficial for qualitycontrol and reverse engineer-

ing applications.To effectively scan surfaces

with varying colour or reflec-tivity, Metris has introducedthird-generation EnhancedSensor Performance (ESP3).ESP3 functionality not just

provides automatic real-timeadjustment of sensor settingsbetween successive laserstripes, but dynamicallyadapts laser source intensity

and camera sensitivity for

each individual point of thelaser stripe. This is achievedthrough rolling shutter imag-ing technology that ensuresmaximum data coverage onall surface materials andshapes, irrespective of sur-

face finishing and lighting

conditions. In case of veryshiny surfaces, a new reflec-tion filter removes fictive scat-tered points resulting in cleanscan data. ESP3 even allowsglossy convex surfaces to be

captured in a single move-ment.

ESP3 offers customizedlaser intensity for each indi-vidual laser stripe point. Withthis capability, LC60Densures maximum data cov-

erage for sheet metal, tur-bine blade, plastic andmachined metal part, wheelrim and many other applica-tions in all lighting condi-tions.

www.metris.com
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PRODUCTS


SURFACE & FORM

Form and surface meas-urement systems con-firm honings stockremoval credentialsThe introduction in the 1970sof superabrasives such ascubic boron nitride (CBN)transformed honing from whatGren Lewis, managing directorof Sunnen Products, describes

as a cleaning-up process to astock removal process capableof removing metal faster andmore accurately than grinding.It is also acknowledged to bea cost-effective alternative toother processes such as hard

turning, reaming and rollerburnishing.

Today it is possible to honevirtually any material, apartfrom lead and wood, with theaerospace industry, for exam-

ple, looking for better thanhalf-a-micron accuracy, he

says. In fact, the latest genera-tion CNC honing systems canproduce hole size accuraciesof 0.25 micron, with minimalvariation and no operatorintervention.

In responding to customers

demands for ever-tighterdimensional accuracies, GrenLewis is adamant that it isessential to be able to meas-ure what it is you are seekingto achieve. This is why thegauge room adjacent to the

machining area in Sunnens1200 sq. m. premises inHemel Hempstead,Hertfordshire, is equipped witha Mahr MarForm MMQ44

Formtester and a MahrMarSurf S2 surface measuringsystem.

The MarForm MMQ44s

high-precision X, C and Zmeasuring axes make it possi-ble to perform any form meas-uring function; monitoringdeviations in geometry or posi-tion for parameters such asroundness, cylindricity,

straightness and parallelism.

Various modules can be usedto configure the system to anend-users exact requirements,whether in semi-automaticmeasuring mode with, forexample, a manual centring

and tilting table, or in fully-automatic measuring mode.The MMQ44 used by Sunnenis fitted with a manual T2Winductive probe, with theprobe arm capable of swivel-ling though 180 and a variety

of clamping possibilities allow-ing access to difficult-to-reachsurfaces, In addition, easilyexchangeable probe armsaccept a wide range of styli forwide measuring versatility.

The MarSurf S2, which

incorporates a dedicatedprocessor, uses the tactile sty-lus method of roughness andwaviness measurement thatallows a two-dimensional pro-file to be calculated and docu-mented to international stan-

dards. It is a semi-portabledevice for roughness andwaviness measurement andevaluation in which the meas-uring conditions are quickly setand saved as a measuringprogram. Pressing two keys

www.nikoninstruments.eu/inexiv

For metrology only aruler is simpler

to use...

...but nothing is morepowerful than a NEXIV

Metrology the science of traceable measurement.In the production environment, the need for speedand convenience often conflicts with requirement foraccuracey, repeatability and cost until now.

With the launch of the new iNEXIV VMA-2520, youcan gain the convenience of a ruler with the accuracyand precision that comes from autofocus-based video

measurement. Just pick, load, measure and respond.

Compact and simple to use

Combines a 250 x 200mm stage

Large working distance

Ideal for rapid QC checks and demanding R&D work

Laser autofocus option for faster measurement speeds

Touch-probe compatible for greater versatility

Ask for a demo now, and run the rule over how thenew bench top iNEXIV VMA-2520 measures up toyour QC challenges.

i N E X I V V M A - 2 5 2 0
http://www.qmtmag.com/http://www.nikoninstruments.eu/inexivhttp://www.nikoninstruments.eu/inexivhttp://www.qmtmag.com/


26/40

MICRO & NANOMETROLOGY

QMT September 08 26

plus START on the keyboardequates to measurement fin-ished, documented andsaved, and an integratedhigh-resolution thermal printer

provides Sunnen with animmediate log of results, pro-

files, curves and lists, as wellas date/time andworkpiece/company texts.

Sunnen carries out exten-sive honing trials in its

Technical Centre prior to anymachine purchase becauseour customers do like to seethat components can behoned to their specification.The best way to check theroundness and concentricity of

any honed component is on acomputer-based form testerand the same applies tochecking surface finish, so thisvery accurate inspection equip-ment is essential because, forour customers, seeing really is

believing.www.mahr.com

Advanced 3D and 4Dsurface texture analysisOlympus and Digital Surf haveannounced an agreement

whereby Olympus will supplyusers of its LEXT OLS3100confocal laser scanning micro-scope (cLSM) with 3D surface

texture and micro-geometryanalysis software based uponDigital Surfs Mountains tech-nology

A Mountains analysis docu-ment is built frame by frame inan intuitive desktop publishing

environment with a multi-lan-guage user interface. Real-

time 3D imaging and intelli-gent pre-processing to max-imise image quality make iteasy to locate and visualise

surface features and anom-alies at any zoom level orangle.

Surface roughness analysisis carried out in accordancewith advanced filtering tech-niques as defined in the ISO16610 standard, including the

new robust filters used by theautomotive industry. A full set

of 3D surface parameters aregenerated in accordance withthe new ISO 25178 standard,the first international standardon 3D surface texture, whichprovides a solid foundation forindustrys transition from 2D to

3D surface analysis.Dimensional checking

includes step heights betweentwo different zones of intereston the surface, for example onMEMS and mechanical com-ponents used in the electronics

and other industries.Moreover, a sub-surface layercan be extracted from a sur-face for independent analysis,e.g. the flatness of an extract-ed layer can be calculated witha single click. Numerous other

analytical studies include:functional parameters used bythe automotive industry, grainsand particle analysis for appli-

cations in metallurgy and nan-otechnology, as well asadvanced statistical options.

In addition to the analysis of

3D surfaces and 2D profilesthat are extracted from them,Mountains provides new func-

tions for analysing the evolu-tion of 3D surfaces withrespect to time or other 4thphysical dimension parameterssuch as temperature, pressure

or magnetic field. In addition,simulated flights over 3D sur-

faces changing in time can beoutput to video for animatedpresentations.

E-mail: [email protected]

www.microscopy.olympus.eu

Improved Helium Ionmicroscope sets newstandards for imaging

resolution & brightness

Carl Zeiss SMT, a leadingglobal provider of electron-and ion-beam imaging andanalysis equipment, has intro-duced a new, improved

Helium Ion Microscope calledthe ORION PLUS. The original

ORION instrument, introduceda year ago, demonstrated thatHelium ion microscopy has auniquely powerful set of fea-tures that allow scientists to

see things never before visible.The ORION PLUS incorporatesseveral design enhancementsthat deliver improved imaging:The tip geometry has beenmodified to increase the accel-erating voltage of the helium

ions, resulting in improved res-olution;

A new Clear View samplecleaning system combinesplasma cleaning, heating ele-ments and an in-situ vapourcleaning technique to remove

hydrocarbons from the sampleand the environment prevent-ing re-deposition in the areabeing scanned, which resultsin increased surface detail;

An enhanced signal collec-tion technique called Signal

Boost increases electron col-

lection at short working dis-

www.visioneng.com+44 (0) 1483 248300

See it. Measure it.Vision Engineerings pioneering range of patented optical and video non-contact measuring sytems provide microscope-

resolution views of the component features you want to measure.

Low contrast? Black-on-black? White-on-white?

No problem... Your measurements will be accurate.

Systems range from simple 2-axis 'shop floor' optical and/or video measuring

microscopes to 3-axis Video Edge Detection measuring platforms.

50 years of Excellence in Ergonomic Microscopy

www.qmtmag.com
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tances for improved signal tonoise; and

An operating mode calledQuiet Mode Imaging is anapproach based on the use of

a cryomechanical pump forcooling the source instead of

liquid nitrogen where userscan virtually eliminate vibra-tion for noise-free images. Thisapproach also provides acolder ion source, which yields

an increase in brightness.Dirk Stenkamp, a member

of the Board of Carl ZeissSMT, said, We are proud ofthe magnitude of improvementwe have been able to achievein only a year of development

since the introduction of thefirst commercially practicalHelium ion beam microscope.We will continue to push theenvelope of advancedmicroscopy, delivering solu-tions that enable scientists to

see and create at the nanome-tre scale.

www.smt.zeiss.com

Increased range ofvariable pressure FESEMHitachi High-Technologiesnew SU6600 variable pressurefield emission SEM furtherincreases its range of highperformance electron micro-scopes. Key to the perform-ance of the SU6600 is the

combination of the advancednew electron gun and novelvacuum control system.

The newly developed

Schottky field emission electrongun can deliver in excess of

200 nA probe current to giveoutstanding analytical resultswith excellent stability and sen-sitivity. The analytical chamberallows the simultaneousaccommodation of EDX, WDX

and EBSD (electron backscatterdiffraction) systems with opti-mum geometry for compre-hensive materials characteriza-tion.

The SU6600 also features

an Automated DifferentialAperture (ADAPT) system,which automatically inserts adifferential pumping aperturefor variable pressure operation

maintaining maximum flexi-bility in high vacuum mode

and ensuring there is no man-ual intervention required whenswitching to low vacuummode. ADAPT operates with asimple mouse click and the

system is designed to ensurethat there is no field of viewrestriction even when the aper-ture is in place to aide lowmagnification navigation andimaging.

Imaging and measurement

capabilities include Hitachishigh-sensitivity, TV-rate 5-seg-ment BSE detector, environ-mental secondary electrondetector (ESED) and an auto-mated 3-D measurement sys-tem. The 3-D measurementsoftware enables fast 3-D visu-

alization of the specimenalong with industry standardheight, area and surfaceroughness measurement.

www.hitachi-hitec-uk.com

MICRO & NANOMETROLOGY

QMT September 08 27

Measurement of steep flanks and complex geometries

True color information registered to 3D data

Traceable results even on highly sculptured surfaces

Usable on highly reflective andinhomogeneous surfaces

Highest resolution across measurementareas of several mm

Comprehensive roughnessmeasurement capabilities, conformingto the latest ISO standards

Usable in the lab and asInline measurement sensor

OPTICAL MEASUREMENT AND INSPECTION

Alicona UK

Alicona UK Ltd.

Lime Tree House

15 Lime Tree Walk, Sevenoaks

Kent TN13 1YH

UK

phone: +44(0)1732 746670

fax: +44(0)1732 465500

e-mail: [email protected]

++ Ra d i i a nd a ng l e me a su r e me n t ++ M e a su r e me n t o f p o l i she d e d ge s ++ Va r i a nc e a na l ys i s ++

www.qmtmag.com
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Anixter Fasteners, the worlds leading sup-plier of industrial fasteners and C-classcomponents to a wide range of indus-

tries, has implemented a tailored enterprise-wide business management system as a unified,single platform solution for quality manage-ment. Operating over 60 sites worldwide andpart of the $6 billion Anixter Inc organisation,

quality management is a keystone to AnixterFasteners global business success.

Although an essential element for AnixterFasteners, quality management has not alwaysbeen an easy process to manage. This is not unex-pected for an organisation of this scale that has60+ sites, many of which include acquired busi-nesses and all with their own particular qualitymanagement systems (QMS) and operating plat-forms. Such was the situation facing Adrian Lloyd

when he took on the role of Global QualitySystems Manager.

Finding a solution to address the integration ofall the different QMSs and the mind-bogglingnumber of records and documents they contained into a single, scalable and flexible system wouldbe a mammoth task. To attain his goal AdrianLloyd would require the cooperation of all thevarious offices and personnel. In addition, hewould need the full support of a meticulous ISdepartment that would quarantine and test anynew solution he proposed to run on the organisa-

tions extensive network.My role was, and remains, to bring all our

quality management into one place so that wecould develop a single company-wide repositoryand resource for quality information. We lookedat several different systems applicable to our sizeof business and we settled on Proquis Enterprise


Global approach to QMS

QUALITY MANAGEMENT SYSTEMS

World leading industrial fasteners company, Anixter Fasteners, has standard-

ised its global quality management system on a single platform solution.


29/40www.qmtmag.com

with the allCLEAR process mapping tool as thesolution to producing a cohesive QMS, saysAdrian Lloyd.

Phased implementationAnixter Fasteners purchased Proquis Enterprise

with allCLEAR process mapping in January 2007.Proquis supplied a range of tailored modules thatwould underpin the fastener companys quality

management approachand its ISO 9001(Quality), ISO 14001(Environmental) and ISO18001 (OccupationalHealth & Safety) accredi-tations. In total the com-pany bought 8 modules: Audit Management

Customer Care Document Control Equipment Control Health & Safety Issues & Actions Personnel Management Supplier Control

The software was testedfor 6 months by the

Anixter IS department, with further testing by thequality management department prior to finalconfiguration. The system went live in January

2008.We are now using and benefiting from themajority of the Proquis modules, including AuditManagement, Document Control, Customer Care,Supplier Control, Issues & Actions which linksacross all the modules and, to some extent,Personnel Management, says Adrian Lloyd.

Audit dividendThe Audit module is fully implemented for inter-nal auditing. This is paying dividends in allowingthe quality management team to take control ofsite audits. We can schedule audits from a cen-

tral point and easily assign auditors to sites. ViaProquis, we are able to see exactly what is goingon for each audit. Moreover, we have been ableto standardise on the audit procedure across theGroup and establish common questionnaires andcommon scoring methods, completely replacingidiosyncratic practices prior to Proquis QMS,says Adrian Lloyd.

The system has helped us to establish andimplement escalation rules for closing out issues.If these are not followed and the issues remedied,then managers are alerted of the outstanding

work. In all this has given us access to a highly vis-ible workflow that we never had before, he adds.

Documentation controlledA business on the scale of Anixter Fasteners gen-erates massive amounts of documentation butwith the Proquis Document Control module

mountains of spreadsheets and manual recordshave been levelled.

We now have an automated approvals processwith all documents held in a single repository.This saves a lot of time in finding the right docu-ment, making changes and gaining approval for

those changes. We simply dont need to keepmanual records anymore as we can view allsuperseded documents within the system, saysAdrian Lloyd. This is a fantastic development forus as it means that instead of trying to manage anduse 9 different paper based quality systems, theteam members are able to use their time to devel-op standardised schemes that we can roll outacross the entire company.

Supplier managementWith the massive range of products that Anixter

Fasteners provides, supplier management is para-mount to quality management. We had 6 differ-ent systems populated with supplier data. Thistook repetition to the extreme. With ProquisSupplier Control, we have reined this in and havetaken a lot of time to clean up the data. Now wehave 4997 clean records on Proquis. The flexibil-ity of the system has allowed us to configure thismodule to support our supply chain developmentprogramme and we are currently populating thesystem with further supplier data such as creden-tials, capabilities, and certification. It will give us

a complete view of everyone we work withthroughout the world, he says.A major boost to efficiency and productivity has

been delivered by the allCLEAR process mappingtool. This enables process maps to be formed usingtext alone, using punctuation to determine the boxtype. This is far quicker and more efficient thandrawing the boxes as required by other softwares.allCLEAR also provides the facility to multi-layerprocesses and link one to another, allowing man-agement systems to be truly integrated.

Proquis has also allowed the quality team toassign ownership to particular documents, which

has provided additional time savings by streamlin-ing the way documents can be worked on andupdated.

Proquis provides us with the ability to engageother departments by allowing them to updatedocumentation themselves. They no longer needto send everything back to Quality Managementfor amending. The system allows full traceabilityand so all changes to documentation can betracked to the originator of each and everyamendment, says Adrian Lloyd.

Six months of use has provided Anixter

Fasteners with benefits that will maintain itsdrive on quality management and strengthenedits competitive edge. Once the remaining mod-ules have been implemented the system will betempered further and will deliver more opera-tional benefits. G

www.proquis.com

29QMT September 08

QUALITY MANAGEMENT SYSTEMS
http://www.qmtmag.com/http://www.proquis.com/http://www.proquis.com/http://www.qmtmag.com/


30/40

The power of a world class supply chain ishelping a West Bromwich manufacturersecure over 1m of new orders from the

aerospace industry. Burcas, which celebrated its65th birthday last year, has embarked on theManufacturing Advisory Service West Midlands(MAS-WM) Lift Off programme to improve per-formance and introduce new processes across

eleven of its closest suppliers, including A&MEDM, Bohler, Carbide Dies Birmingham andTamworth Heat Treatment.

The closer working relationships have had animmediate effect on efficiency and communica-tion, not to mention playing a crucial role in con-tracts for Hentons, Hampson Aerospace andSumitomo Precision Products the latter focusingon the production of landing gear parts for theAirbus A330.

Black Country based Burcas has a turnover ofover 6m and employs around 80 people. Its

work with the aerospace industry has increasedsince the loss of key automotive contracts in theregion over the past few years, although the com-pany has not lost touch with its roots and still pro-duces a number of traditional products, includingprecision tools and paper-cutting knives.

On the shift to a niche industry, Mike Burrows,

managing director, is delighted at the progress todate: The nature of our business means that weare continually looking to target new markets andthis was one of the key considerations behind ourlogic for taking part in the Supply ChainDevelopment Programme.

He continued: Aerospace suited our ability toproduce precision parts and we quickly identified

a need to embrace six sigma and lean enterprisepractices, in order for us to gain accreditationsand be able to conform to the strict quality stan-dards expected.

We got talking to Bob Reeve at MAS-WM andhe introduced us to the Lift-Off project, whichwould provide funding towards the creation of aworking group of suppliers that could learn fromeach other and an external consultant to becomemore competitive. It was an easy decision tomake.

Industry leaders, TEC Transnational, were

brought in to deliver the programme and identifykey goals for each individual company and howthis impacted on Burcas performance.

A series of AS9100 approved six sigma trainingcourses were delivered, whilst a tailored pro-gramme of activities improved supplier perform-ance and encouraged a change agent culture


Lift off for Burcas

SIX SIGMA & LEAN

A supply chain development programme based on a six sigma and Lean

approach leads to a 1m aerospace contract for Burcas

Photo (from left)David Scrimshire

(TEC), MikeBurrows (Burcas)mark Wingfield

(A&M EDM), PaulRandle (Tamworth

Heat Treatment)and Bob reeve

(MAS -WM)


31/40

The World Trusts Minitabfor Quality

3M

Avery Dennison

Black & Decker

Boeing

Eastman Kodak

ExxonMobil

Ford Motor Company

General Electric

Hewlett-Packard

Monsanto

Multibras Eletrodomesticos SA

Samsung Aerospace

Toshiba

Whirlpool

Plus the leading Six Sigma

consultants and more than 4,000

colleges and universities worldwide.

To speak with a Minitab representative, call +44 (0)24 7643 7500 or e-mail [email protected]

The best way to deliver better products and services

is to use Minitab Statistical Software to analyse and

improve your processes.

Quality professionals worldwide use Minitab because it:

Contains the essential methods, including Descriptive Statistics,

Statistical Process Control (SPC), Process Capability, Gage R&R,

and more.

Produces vivid graphsthat clarify every phase of a project.

Is easy to use,thanks to its intuitive interface and features like

StatGuide and ReportPad which help you interpret and present

your results.

Comes with flexible licensing options and free technical support.

Try Minitab 15 free for 30 days!

To learn more, visit www.minitab.co.uk

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mailto:[email protected]:[email protected]://www.minitab.co.uk/http://www.minitab.co.uk/http://www.minitab.co.uk/http://www.minitab.co.uk/mailto:[email protected]


32/40


33/40

PRODUCTS


SPC & DATA COLLECTION

Flexible connectivity toolZontec Inc. has releasedSynergy 2000(TM) Multi-func-

tion Toolbox, a data integra-tion program that interfaces itsstatistical process control (SPC)

software with a variety ofmulti-vendor hardware plat-forms and manufacturing sys-tems.

Using the Toolbox, Synergy

2000 users can achieve com-patibility with previously isolat-ed systems, enabling them toeasily perform SPC charting,analysis, traceability andreporting on any data regard-less of its origin. It is a com-

plete plug-and-play modulethat requires no additional

programming or software cus-tomization of the Toolboxcode.

The Multi-function Toolbox isdesigned for:

* Real-time data collectionfrom CMMs, PLCs and otherprocess control devices

* Integrating data from ERP,LIMS, SCADA and other man-ufacturing systems

* Migrating legacy data

from other SPC programs,business applications anddatabases

* Creating multiple Synergy2000 Data Table instances atone time

* Bridging OPC servers and

the Synergy 2000 OPC client* AIAG (Automotive Industry

Action Group) QualityMeasurement Data (QMD)support for standard gaugingdevices

The Synergy 2000 Multi-

function Toolbox was devel-oped within the Microsoft.NET(TM) programming envi-ronment for applications thatconnect seamlessly from the

plant floor to the Data Center.

www.zontec

Measurement softwareincludes analog gaug-ing & QDAS certificationA new version of GageMetrics,the precision measurementsoftware from ASI DataMyte,includes the ability to commu-nicate with analog gauging,including LVDT probes.

GageMetrics Version 2.0now works seamlessly with theASI DataMyte Model 916Precision Gaging Multiplexerto interface with standardLVDT analog probes and high-frequency miniature IET

probes. The new version alsosupports Marposs DigiCrowndigital probes in addition toSolartron Orbit probes.

With the release of Version2.0, GageMetrics Software isalso Q-DAS certified. The Q-

DAS ASCII data transfer for-mat alow comparison of datafrom a variety of measurementsystems without complications,allowing for consistent datamanagement and analysis. In

addition to the Q-DAS FileExchange format, GageMetricsalso exports data in other for-mats: -

- ASI DataMyte GAM Files

used by ASI DataMyte Importerto insert data into the database

- Text files used for ASIDataMyte DataMetrics soft-ware and Microsoft Excel toperform in-depth analysis

Before the availability of

GageMetrics, many precisionmeasurement applicationsrequired a steep learningcurve and many trial and errorsessions before they could beimplemented on the shopfloor. GageMetrics uses clear

and simple colour-codedgraphics that minimize trainingtime, startup time and thepotential for operator error.These features also minimizedifferences from one user tothe next, ensuring reproducibleresults across different opera-

tors and shifts. Data from bothtypes of applications is storedin the same networkable data-base for analysis and correla-tion studies.

www.asidatamyte.com
http://www.qmtmag.com/http://www.asidatamyte.com/http://www.tiniusolsen.com/http://www.asidatamyte.com/http://www.qmtmag.com/


34/40

Finding a snail in a salad, a fish bone in a sup-posedly boneless fillet or opening a souppacket to reveal mouldy contents is an

unpleasant and potentially unsafe experience.Small foreign bodies and packaging defects arefrequently not detected by food producers, but anew X-ray inspection technology developed byEuropean researchers is ensuring that the onlything in peoples dinners is the food itself.

For consumers, a more effective method ofinspecting food products before they reach super-market shelves means better-preserved and clean-

er food on their dinner tables and a reduction inthe risk of food poisoning.

An improved inspection system also means pro-ducers can offer better quality produce, reducethe risk of spoilage, and gain a competitive edgeover rivals.

Already in use commercially, the technologydeveloped by the Modulinspex project uses low-energy X-rays to produce highly detailed imagesof food products and packaged goods. The images

are then scanned via inspection software that canautomatically detect any irregularities accuratelyand quickly.

The system can be used to check seals on foodwrappers, locate packaging defects and find for-eign particles of any size in any kind of food, frommaggots in apples to grains of sand in bread.

Even in an era of high food standards and ster-ilised packaged produce, those problematic for-eign bodies and packaging flaws are more com-mon than most people realise, says JrgenRheinlnder, the managing director of Denmark-

based InnospeXion, which helped develop thetechnology. Rheinlnder was the project coordi-nator for Modulinspex.

Go down to your supermarket and pick up apackage of dried pasta, he says. About one in tenwill have pieces of pasta trapped in the seal that canlet air and moisture in and spoil the product.Rheinlnder notes, for example, that some bacteriamay spread on poorly sealed produce and go unno-ticed by consumers until they end up spending the


Food inspection gets better

X-RAY INSPECTION

New inspection X-ray technology developed by European researchers is

helping to ensure that the only thing in peoples dinners is the food itself.


35/40www.qmtmag.com

next day on the toilet or at the hospital.

Lower energy, higher definitionUntil now X-ray inspection technology used byfood processors was dominated by high-energyintensity systems not unlike those used to scan

luggage at airports. These are able to detect a peb-ble in a package of corn but lack the resolution topick out a grain of sand in a bag of flour.

The higher-resolution alternative, low-energy X-rays, had not been used because it took too longto scan the produce and would slow the rapidpace of production in modern processing andpackaging plants.

The European researchers working in the EU-funded Modulinspex project have brought bothgreater speed and accuracy to the table.

By attaching a CMOS chip to the crystal that

detects the X-rays in a low-energy system theyhave been able to build a detector capable of tak-ing 300 images per second, enough to capture acrisp image of products moving on a conveyorbelt at half-a-metre per second. The X-ray imageshave a resolution of 0.1 millimetres 16 timesbetter than existing high-power systems, making itpossible to detect objects as small and fine as aherring bone.

The system is also modular, allowing hardwareand software components to be adapted to suit the

needs of

any producer in the food industry.Most X-ray luggage scanners at airports are vir-

tually identical because one type works any-where, Rheinlnder explains. In the food indus-try, however, everyone has different requirementsdepending on the speed of the production line,

the type and size of products being scanned andhygiene regulations.

The consortium of companies involved in theproject has already sold three of their systems tocompanies in Spain, the United Kingdom andDenmark. The systems were bought after the proj-ect partners held a demonstration at theScandinavian Food-PharmaTech exhibition lastNovember in Denmark. Curiously, none of thethree systems that were sold are being used in thefood sector, confirming, in Rheinlnders view, thebroader range of applications for the technology. In

the UK, for example, the system is being used by acompany to inspect filters delivered by an outsidesupplier, while in Denmark it is being used tocheck the quality of fur used to make coats.The market for this technology is truly enor-mous, he says. In the food industry alone wecan expect growth rates in excess of 20% andwe also see a market for using it in manufacturing,to inspect seals on car components, for example,or to check for counterfeit products.G

Adapted from materials supplied by ICT Resultshttp://cordis.europa.eu/ictresults

35QMT September 08

X-RAY INSPECTION

SURFACE MEASUREMENTWITH A DIFFERENCE

SkidlessTHAT'S THE KOSAKA WAY!

A metrology surface analyser

at workshop prices

Small bores

Grooves

Lands

CurvesWaveform

Straightness

Step heights

To International

Standards

A Surfcorder SE-1200 with 4styli will measure most typesof surface roughnessparameters with printoutof results and graphs.Why pay more for less!!

METROLOGY INTERNATIONAL LTD8 COLD BATH RD, HARROGATE, HG2 ONA

Send us an email [email protected] our website: www.metrologyinternational.com

Participants in Modulineex

are:

Oy Ajat Ltd., Finland

Cavendish Instruments Ltd.,

UK

Zenon S.A. Robotics and

Informatics, Greece

Detectronic A/S, Denmark

Institute of Electronics and

Computer Science,

University of Latvia

picture:www.p

hotocase.de

Material Testing

So that theykeep flyingSo that theykeep flyingKnowledgeable people trust themsel-ves and the safety reserves of thematerials. Destructive testing of ma-

terials shows its limits, making safetymeasurable.

Testing machines and systems:

we have the know-how.

Zwick GmbH & Co. KGAugust-Nagel-Strae 11

D-89079 Ulm/GermanyPhone: +49(0)7305-100

Fax: +49(0)[email protected]

Intelligent testing
http://www.qmtmag.com/http://cordis.europa.eu/ictresultsmailto:[email protected]:[email protected]:[email protected]://www.metrologyinternational.com/mailto:[email protected]:[email protected]:[email protected]:[email protected]://www.zwick.com/mailto:[email protected]://www.zwick.com/http://www.zwick.com/mailto:[email protected]://www.metrologyinternational.com/mailto:[email protected]://cordis.europa.eu/ictresultshttp://www.qmtmag.com/


36/40

PRODUCTS


MATERIALS TESTING

Do toys pose a risk forour children?A toy is defined in law as aproduct intended for childrenunder 14 to play with. Everyyear thousands of new toysenter the market and as par-ents we dont expect them to

harm our children, but howcan we be sure?

Since January 1, 1990, toys

can only be placed in theEuropean market if they bearthe CE Mark. Toy manufactur-ers are therefore under a legal

obligation to ensure that theirproducts are thoroughly tested,and they and their dealershave special tests performedby organisations such as LGAin Nuremberg, Germany.After successful results the LGA

can also award the GS(geprfte Sicherheit = certifiedsafety) mark.

Using a Zwick Z005 testingmachine equipped with a500N load cell, LGA carriesout many mechanical tests

which enable everyday situa-tions which might arise in theplayground or home to besimulated in the laboratoryunder controlled conditions.

One example is when achild tugs at a stuffed dogsmuzzle with its teeth. The

muzzle must remain fully

attached even when a tensileload of 90N (9kg / 20lbs) isapplied using the Zwickmachine. With other toys it isabsolutely vital that no smallparts can become detached,

as swallowing them can be

fatal for children. Subjectingparts of the toy to such pulling,pushing, tearing, bending, andcycling forces is childs playusing latest Zwicks testXpertII software because all theimportant parameters of the

test machine such ascrosshead speed, travel dis-tances, required force

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Quality Manufacturing Today Magazine September 2008

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