Quality April 2011

April 2011, Volume 50/Number 4 www.qualitymag.com

50 Years of Quality: Surface Finish p. 28

Digitize Test Samples for Measurable Improvements p. 36

When It Comes to Measuring, First Things First p. 32

Is Your Process Performing? p. 40

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Forrest W. Breyfogle III p. 44

For interviews with the 2011 Quality Professional of the Year, listen to Quality podcasts at www.qualitymag.com/q-cast

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CONTENTS

APRIL 2011 VOLUME 50/NUMBER 4

DEPARTMENTS 6

From the Editor Going Virtual

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Industry News Tech ManufactureXPO Debuts May 4

Source: Mahr

 2011 Global Automotive Outlook Positive

28

 Study Finds Outsourcing Losing Favor

14 Face of Quality

FEATURES 50 YEARS OF QUALITY

28 A Superficial History of Surface Finish Any number of influences can leave their mark on the surface of a part. The result is a microscopic maze of etchings that detail the history of a part’s manufacture.

QUALITY MEASUREMENT

32 When It Comes to Measuring, First Things First Whether measuring with calipers—or large-volume scanners—basic knowledge of dimensional metrology first principles enables better results.

QUALITY TEST & INSPECTION

36 Strength in Numbers Digitizing test samples allows for measureable improvements in process, productivity and quality.

QUALITY SOFTWARE & ANALYSIS

40 Is Your Process Performing? Discover the most common SPC errors and learn how to correct them.

QUALITY MANAGEMENT

44 Ask the Right Questions 2011 Quality Professional of the Year Forrest Breyfogle III is the CEO of best practices consulting company Smarter Solutions Inc., author of multiple books that empower businesses to lead effectively and the innovator of the Integrated Enterprise Excellence System—a process that lies at the heart of these achievements.

Mentoring Improves Organizations

16 Other Dimensions Calibration Mistakes: Plain Plug Gages

23 Quality 101 The Whys and Hows of Flowcharting

26 Quality Innovations Total Quality Tool

48 Case Study New CMMs Lend Throughput Advantage

50 Quality Products 57 Classifieds 60 Advertising Index

NEXT MONTH  CMMs  Noncontact Inspection  ISO Standards  Training

ABOUT THE COVER Forrest W. Breyfogle III, the 2011 Quality Professional of the Year, is creator of the Integrated Enterprise Excellence (IEE) methodology—a system that blends the analysis of Six Sigma thinking with a foresight for innovation. Source: Smarter Solutions Inc.

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QUALITY | April 2011

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

A P R I L 2011

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QUALILITT YMAG.COM 7 Steps of DOE Design of Experiments (DOE) is effective as a troubleshooting method because it helps understand a process in more detail. Follow these seven steps when conducting experiments. Automated Programming Simplifies Processes Seimens PLM Software’s integrated development process shortens cycle times while fostering innovation.

The Metrotom CMM: A Unique Metrology Solution April 20, 2:00 p.m. ET How Can Optical Measurement Improve Industrial QC? May 12, 2:00 p.m. ET

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Scanning a “Bot” from Mystery Science Theater 3000 Mystery Science Theater 3000, an award-winning television comedy, wanted to create a 6-inch figurine of one of the show’s robot characters. The process had to be nondestructive because there was only one puppet of the character. 3-D laser scanning provided an accurate, detailed model.

CONNECT WITH QUALITY:

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

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

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

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

NOW PLAYING ON Q-CAST

NOW PLAYING ON Q-TUBE

Interview with Quality Professional of the Year

IMTS Revisited • Carl Zeiss • Marposs • Micro-Vu • Nikon Metrology • S-T Industries

Quality Leadership 100 Companies Laser Radar Slashes Inspection Time Remote Visual Inspection Equipment

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QUALITY | April 2011

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F RO M T HE EDI TOR

BY GIL L IAN C A MP B E L L

Going Virtual W

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

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

e are just a few short weeks way from Quality’s first virtual tradeshow, Tech ManufactureXPO. Held in conjunction with other BNP Media publications—Assembly, Adhesives & Sealants Industry, CircuiTree and World Trade— Tech ManufactureXPO promises to be an educational experience right at your fingertips. Tech ManufactureXPO takes place Wednesday, May 4, from 8:30 a.m.-3:30 p.m. ET. Register today at www.techmanufacturexpo.com. For those not familiar with the concept, a virtual expo is a gathering of people sharing an online environment to create an interactive experience. It can be considered the online equivalent of a traditional trade show. This is the opportunity for you and your entire team to interact one-on-one with others focused on manufacturing technology. Just log onto your computer on May 4 and join the expo with all these benefits: • No travel or registration fees so you can attend with your whole team. There’s no need to draw straws to see who stays in the office and who spends time walking the show floor. Everyone can attend. • No time spent out of the office. The show can be attended from any computer with an Internet connection throughout the day. • Reach multiple suppliers with the click of a button. Many suppliers will be on hand to answer your questions. • Chat one-on-one with your manufacturing peers. Share ideas with your peers across the street or across the world. • Download free whitepapers, case studies, pod-

casts and more. This is a great educational experience at no cost to you. The first keynote address speaker, Harry Moser, will present “Reshoring: A Key to Lower Costs, More Sales and a Stronger Economy,” at 9:00 a.m. ET. Moser is the founder and leader of the Reshoring Initiative. Following his presentation, Moser will be available at 9:45 a.m. ET for a live 15minute Ask the Expert Chat. In addition to a great speaker lineup, the editors of the sponsoring magazines will be participating in a live, interactive roundtable Lunch-n-Learn session, from 12:30 to 1:00 p.m. ET, focusing on the trends in green manufacturing. Wrapping up the technical sessions at 2:30 p.m. ET will be a session on reverse engineering featuring Paul Jr. Designs. Sponsored by Faro, this webinar will demonstrate how to use a portable coordinate measuring machine (CMM) for the reverse engineering of parts. Paul Jr. and Vinnie of Paul Jr. Designs will share their experiences using a CMM and how it has improved their reverse engineering processes. Following the presentation, will be a 15-minute Ask the Expert Chat with Faro, Paul Jr. and Vinnie. * * * * * I would be remiss if I didn’t mention that Other Dimensions columnist Hill Cox has reached a milestone—100 columns. Hill’s first column appeared in February 2003. Turn to p. 16 for his latest rantings and ravings. Hill, thanks for keeping us entertained 100 times over.

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QUALITY | April 2011

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CORPORATE DIRECTORS Publishing: Timothy A. Fausch Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Conferences & Events: Emily Patten Clear Seas Research: Beth A. Surowiec

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

COMING EVENTS MAY 1-5 ANTEC 2011 Boston, MA Society of Plastics Engineers (203) 740-5452 www.antec.ws 3-6 CONTROL: INTERNATIONAL TRADE FAIR FOR QUALITY ASSURANCE Stuttgart, Germany Six Offene Systeme GmbH +49 7261 689-900 www.schall-messen.de/en/1353 4 TECH MANUFACTURE XPO Online only BNP Media (248) 362-3700 portfolio.bnpmedia.com/virtual 10-13 ULTRASOUND WORLD VII Clearwater Beach, FL UE Systems Inc. (914) 592-1220 www.uesystems.com 17-19 EASTEC 2011 West Springfield, MA Society of Manufacturing Engineers (313) 425-3000 www.easteconline.com

JUNE 2-6 HEXAGON 2011 Orlando, FL Hexagon (800) 730-4647 www.hexagonconference.com

TECH MANUFACTUREXPO TO DEBUT MAY 4 TROY, MI—Tech ManufactureXPO will occur on May 4 from 8:30 a.m. to 3:30 p.m. Eastern standard time. It is a virtual expo that can be considered the online equivalent of a traditional trade show. Attendees can reach multiple suppliers with the click of a button, chat oneon-one with manufacturing industry colleagues and download free whitepapers, case studies and podcasts. Tech ManufactureXPO also will include a keynote address from Reshoring Initiative founder Harry Moser. The Reshoring Initiative is a nonprotectionist effort to reduce American imports, increase net exports and regain manufacturing jobs. Going local can reduce a company’s total cost of ownership (TCO) of purchased parts and tooling and offer a host of other benefits while bringing U.S. manufacturing jobs back home. The Initiative documents for large manufacturers the benefits of sourcing in the United States. Archstone Consulting’s 2009 survey showed that 60% of manufacturers use “rudimentary total cost models” and ignore 20% of the cost of offshoring. The Initiative is providing its TCO Estimator software free to help OEMs compare the true TCO of local vs. offshore sources and to help job shops sell the benefits of local sourcing to their customers.

Tech ManufactureXPO is geared toward global manufacturers, formulators and end-users of adhesives and sealants. Potential attendees run the gamut of the manufacturing industry, and include manufacturing professionals responsible for engineering and managing product assembly operations throughout the original equipment market. Register today at www.techmanufacturexpo.com.

GLOBAL AUTOMOTIVE OUTLOOK FOR 2011 APPEARS POSITIVE WESTLAKE VILLAGE, CA—Global new light-vehicle sales this year are projected to reach 76.5 million units, which would surpass the record of 72 million light vehicles sold 2010, according to J.D. Power and Associates Automotive Forecasting. If new light-vehicle sales reach their expected levels, this would be 6% higher than the 2010 total, which shattered the previous record of 70 million units set in 2007. “Overall growth in the world economy has been supporting further recovery in auto sales,” says John Humphrey, senior vice president of automotive operations at J.D. Power and Associates. “We’re seeing signals of stability and increased consumer demand for new vehicles as economic optimism increases.” Most regions saw sales growth in 2010, including North America, South America and Asia, with China being a key to growth for that continent. West-

View the latest in quality industry news by visiting our headlines at qualitymag.com—updated daily. Just click the tag now and see what you’re missing. If you don’t have the mobile app on your smart phone, visit http://gettag.mobi to get started.

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QUALITY | April 2011

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ern Europe was the notable exception to the growth pattern, as its sales suffered when the government-sponsored vehicle-scrappage programs expired in 2010. For the first time in 2010, emerging auto markets accounted for more than one-half of global light-vehicle sales—51% —clearly signaling the shift of power in the global automotive market that has been taking place during the past five years. That momentum in the emerging markets is expected to continue throughout 2011.

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STUDY FINDS OUTSOURCING LOSING FAVOR CHICAGO—According to a study by BDO USA LLP, an accounting and consulting organization, 35% of U.S. technology companies surveyed are currently outsourcing services or manufacturing to companies outside of the United States. This represents a 43% decrease from the 2009 high when 62% of companies were outsourcing and a slight decline from 2010 (37%). The study of 100 CFOs also found that of the companies who are not currently outsourcing (65%), the majority would not consider outsourcing beyond their backyard (58%), either choosing the United States, (25%), Canada (13%) or indicating no plans to outsource at all (20%). And while some U.S. regulations have CFOs concerned (83% note concern with the changing national tax landscape), jobs and operations are not expected to head overseas any time soon. “Outsourcing can be looked at as a bellwether of the economy,” says Don Jones, partner in the technology and life sciences practice at BDO. “Tech companies turned to outsourcing in 2009 in order to reduce operating costs and ride out the recession. Since then, we’ve seen a marked decrease as companies recover and look to create jobs and growth close to home.” These findings are from the fourthannual BDO Technology Outlook Survey, which examines the opinions of 100 chief financial officers at leading technology companies located throughout the United States.

MANUFACTURING TECHNOLOGY CONSUMPTION UP 85% IN 2010 MCLEAN, VA and ROCKVILLE, MD—December U.S. manufactur-

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BUSINESS NEWS Phillips Service Industries Inc. (Livonia, MI), a global manufacturing and service corporation that serves a wide variety of industries with its diverse collection of technology-based companies, has acquired Skytronics Inc. (El Segundo, CA), a leading aircraft component manufacturer and maintenance repair organization. Renishaw Ltd. (Hong Kong) has won the Best Supplier award at the 2010 China Higher Educational Equipment Supplier Evaluation. Renishaw, with the inVia Raman microscope, is the first and only Raman spectroscopy supplier to win this award. The award was presented by the Higher Educational Laboratory Research Society, whose review and inspection committee comprises experienced professors, spectroscopy experts and user representatives from well-known universities in China. Olympus (Center Valley, PA) will begin selling its biomedical and industrial microscopes and imaging instruments directly throughout 14 additional states, including Arizona, Colorado, Idaho, Iowa, Minnesota, Montana, New Mexico, North Dakota, South Dakota, Texas, Utah, Wisconsin, Wyoming and Michigan. 2011 marks the 30th anniversary of the founding of Sciemetric Instruments (Ottawa, Canada) whose technology has been used by some of the world’s largest manufacturers to improve quality and their manufacturing processes. The company’s process monitoring and quality management systems and software help manufacturers monitor the variables that impact critical manufacturing processes. This, in turn, enables them to improve product quality and maximize profitability.

ing technology consumption totaled $446.76 million, according to The Association for Manufacturing Technology (AMT) and the American Machine Tool Distributors’ Association (AMTDA). This total, as reported by companies participating in the USMTC program, was up 40.9% from November and up 104.8% when compared with the total of $218.16 million reported for December 2009. With a year-to-date total of $3,236 million, 2010 is up 85.3% compared with 2009. These numbers and all data in this report are based on the totals of actual data reported by companies participating in the USMTC program. “For the first time in USMTC history, we experienced four months of consecutive growth following IMTS, ending the year on a solid upswing,” says Douglas K. Woods, president of AMT. “2010 orders closed strong, up

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QUALITY | April 2011

Dickten Masch Plastics (DMP, Nashota, WI), a custom Wisconsin and Iowa-based thermoplastics and thermoset molder with metal stamping and assembly capabilities, recently earned ISO/TS 16949: 2009 certification as a Tier 1 automotive supplier. The certification validates DMP’s commitment to its customers and to the continuous improvement. The registration also will support DMP’s Fluid Level Indicator business to Tier 1 automotive OEMs. Spitzer Industries Inc. (Houston) announced the completion of its acquisition of Advanced Inspection Technologies (AIT, Melbourne, FL). AIT specializes in performing advanced nondestructive testing (NDT) of welds and base materials, using phased array ultrasonic testing and computed radiography. The acquisition also furthers Spitzer’s fabrication capabilities with deeper welding engineering and technology capabilities. InterTech Development Co.’s (Skokie, IL) testing applications laboratory is making free engineering and costprojection reports available to quality assurance engineers. These are application-specific reports intended to help engineers gage the costs of integrating multiple facilities worldwide while still maintaining ISO 9001, ISO 12485: 2003 and other quality standards. AV&R Vision & Robotics Inc. (Montreal, Canada) won contracts worth more than $1.5 million from two major European players in the jet engine industry. AV&R will install surface inspection systems in Germany and England. AV&R specializes in gas turbine manufacturing solutions in robotic material removal and automated surface inspection.

85% over 2009, and December’s orders were 40.9% higher than the previous month. With backlogs firming and quotation levels accelerating, we are very optimistic that the industry will see strong results in 2011.” The U.S. Manufacturing Technology Consumption (USMTC) report, jointly compiled by the two trade associations representing the production and distribution of manufacturing technology, provides regional and national consumption data of domestic and imported machine tools and related equipment. Analysis of manufacturing technology consumption provides a reliable leading economic indicator as manufacturing industries invest in capital metalworking equipment to increase capacity and improve productivity.

PLAN OUTLINES NIST R&D GRANTS GAITHERSBURG, MD—The National Institute of Standards and Technology

(NIST) has posted a three-year plan outlining the topics of possible future competitions for research and development (R&D) funding under the agency’s Technology Innovation Program (TIP). The research funding roadmap, which looks three years past the current fiscal year, proposes a range of TIP competitions in the fields of civil infrastructure, manufacturing, energy, health care, water resources, complex networks and sustainability. “We are posting the TIP three-year plan to keep our user community— industrial and academic research groups in this case—informed of our current plans for future R&D funding competitions,” says NIST Director Patrick Gallagher. “But I want to stress that these are not engraved in stone. If you have better ideas, we’d like to hear from you.” TIP was created to foster novel technologies to meet the nation’s critical

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needs, and supports President Obama’s commitment to winning the future by out-innovating, out-educating and out-building our global competition. The White House launched the Startup America initiative with a focus on innovation and a plan to encourage private sector investment in job-creating startups, accelerate breakthrough research and address barriers to success for entrepreneurs. The program provides cost-shared funding, on a competitive basis, for high-risk technology R&D that offers solutions to specific critical national needs identified by TIP. Program officials emphasize that the threeyear plan is not a formal solicitation for proposals. There are no current TIP competitions. TIP funds cost-shared R&D projects by single small-sized or medium-sized businesses or by joint ventures that also may include institutions of higher education, nonprofit research organizations and national laboratories. TIP awards are limited to no more than $3 million total throughout three years for a single company project and no more than $9 million total throughout five years for a joint venture. Proposed TIP competition topics through FY 2014, according to the plan, would include advanced sensing technologies and advanced repair materials for civil infrastructure; advanced materials, biomanufacturing and manufacturing processes and robotics and intelligent automation for manufacturing; technologies to enable a smart grid; technologies for personalized medicine; technologies for water availability; complex networks; and sustainability.

PEOPLE NEWS TRW Automotive Holdings Corp. (Liviona, MI) has appointed its president and CEO John C. Plant to the additional post of chairman of the board. Plant has held the position of president and CEO and has been serving as a member of TRW’s board since 2003. NP Photonics Inc. (Tucson, AZ), an advanced fiber laser products company for sensing and metrology applications, has appointed Terry Hannon to the role of president and CEO. Hannon most recently served as vice president of NP, where he was responsible for marketing, sales and corporate strategy. Creaform (Lévis, Quebec) has appointed Stéphane Galibois to the role of vice president of technology sales for North America. Galibois will take charge of business development and strategic accounts for the region. He also will oversee Creaform’s team of sales specialists and distribution network for the continent. Yokogawa Corp. of America (Houston) has appointed Chet Mroz to the role of president and COO of Yokogawa’s North American operations. Mroz is based in the Sugar Land, TX, office and is responsible for all day-to-day operations in North America. Methods Machine Tools (Sudbury, MA) has appointed Michael Minton to the position of national applications engineering manager. He will be responsible for coordinating the national applications and automation services throughout North America.

Chet Mroz

IPG Photonics Corp. (Oxford, MA) has appointed Chris Pilcher to the role of sales manager for Canada. Pilcher has experience selling industrial lasers and systems to OEMs, integrators and end-users, most Michael Minton recently with Trumpf Canada Inc.

FORD REPORTS 2010 FULL YEAR NET INCOME OF $6.6B DEARBORN, MI—Ford Motor Co. reported 2010 full year net income of $6.6 billion, or $1.66 per share, an increase of $3.8 billion, or 80 cents per share, from 2009. This was Ford’s highest net income in more than 10 years, as strong products and new investments fueled improvements in all of the company’s business operations around the world.

“Our 2010 results exceeded our expectations, accelerating our transition from fixing the business fundamentals to delivering profitable growth for all,” says Alan Mulally, Ford president and CEO. “We are investing in an unprecedented amount of products, technology and growth in all regions of the world.” Full year 2010 pre-tax operating profit was $8.3 billion, or $1.91 per share, an increase of $8.3 billion,

ASSOCIATION NEWS The Society of Manufacturing Engineers (SME, Dearborn, MI) is recognizing Robert V. Petrach Jr.,CMfgE, with the 2011 Award of Merit for the contributions he has made to the his local chapter, affiliated chapters and the Society overall. Petrach, an injection molding manager at Safety Technology International (Waterford, MI) was nominated for this recognition by members of SME’s Oakland-Macomb No. 69 chapter for his dedication and great enthusiasm for manufacturing engineering. The award of merit is bestowed on outstanding SME members who, in the judgment of the International Awards & Recognition

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QUALITY | April 2011

Committee, have made valued, balanced contributions to the Society’s professional activities and growth. The Coordinate Metrology Society (CMS, Benbrook, TX), the membership association for measurement professionals, will hold its 27th Annual Coordinate Metrology Systems Conference (CMSC) July 25 to 29, 2011, at the Arizona Biltmore Hotel and Spa in Phoenix. This five-day event is designed for users of portable 3-D coordinate measurement solutions utilized on manufacturing factory floors or by science laboratories. To register, visit www.cmsc.org.

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or $1.90 per share, from a year ago. This increase ref lects a profit in each automotive segment led by strong performance in North America, ref lecting primarily favorable volume and mix as well as favorable net pricing. Ford Credit’s strong profit also contributed significantly to Ford’s full year performance. Ford made significant progress in strengthening its balance sheet, reducing automotive debt by $14.5 billion in 2010, a 43% reduction. These actions will lower annualized interest expense by more than $1 billion. Ford finished the year with automotive gross cash exceeding debt by $1.4 billion. Fourth quarter actions reduced automotive debt by $7.3 billion, including $2.5 billion of newly announced debt reductions to pay down Ford’s revolving credit facility and term loans. Ford reported fourth quarter net income of $190 million, or 5 cents per share, a decrease of $696 million, or 20 cents per share, from the fourth quarter of 2009. This includes the negative impact of special items of $1 billion, primarily associated with a previously disclosed $960 million charge related to the completion of debt conversion offers that reduced outstanding automotive debt by over $1.9 billion. As a result of Ford’s 2010 financial performance, the company will pay profit sharing to approximately 40,600 eligible U.S. hourly employees. The average amount is expected to be approximately $5,000 per eligible fulltime employee. “The progress that we made improving our core automotive business has allowed us to strengthen significantly the balance sheet in 2010, and this will remain a key area of focus for us in 2011,” says Lewis Booth, Ford executive vice president and chief financial officer. “We continue to manage the business for long term profitable growth.”

was named special assistant to the president for manufacturing policy within the White House’s National Economic Council. Bloom has been the administration’s auto czar since 2009 and has overseen the auto industry restructuring. AMT’s President Douglas K. Woods is optimistic that the move is a step in the right direction toward establishing a national manufacturing strategy.

“For nearly two years, and as part of our manufacturing mandate, AMT has been advocating for the appointment of a senior position on manufacturing policy at the White House,” says Woods. “I’m hopeful this is recognition from the administration that job creation and competitiveness depend on a national agenda that emphasizes the importance of manufacturing.”

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AMT APPLAUDS NEW POST FOR MANUFACTURING POLICY MCLEAN, VA–The Association for Manufacturing Technology (AMT) applauds President Obama’s creation of a new post overseeing manufacturing policy. Ron Bloom

www.qualitymag.com

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April 2011 | QUALITY

13

FACE O F QUA LI T Y

BY J IM L . SMI T H

Mentoring Improves Organizations Mentoring is a leadership tool that helps develop an organization’s managerial talent. Jim L. Smith has more than 45 years of industry experience in operations, engineering, research & development and quality management. You can reach Jim at [email protected].

Q

uality professionals face tough obstacles and unique challenges. They often need special leadership attention but don’t always receive it. That is where mentoring can make a difference. Mentoring is a leadership tool that helps develop an organization’s managerial talent through interaction between a mentor and a mentee (or protégé). When mentoring, formally or informally, a manager with experience, expertise and wisdom teaches, counsels and helps a less experienced or less knowledgeable person to develop professionally and personally. Mentors ensure younger or less experienced managers are competent and committed to organizational goals. Mentors also have a vocational and psychological impact on the mentee.

Continuous improvement is enhanced through the technical and the human side of quality.

Vocational benefits include: • Sponsorship. A mentor, who can work best when the mentee is not in a subordinate relationship, supports the mentee with his personal reputation. • Exposure. Ensure the mentee’s talents are showcased and developed. • Protection. Shield the mentee from political pitfalls. • Challenges. Assign the mentee to projects or opportunities that will stretch and develop the mentee. Some of the psychological benefits include: • Role modeling. Set an example of how to behave within the organization. • Confirmation. A mentor can be a risk-free sounding board for the mentee. • Counseling. Advise the mentee on what to do and what not to do. This helps the current performance but prepares the mentee for future assignments of greater responsibility. • Friendship. Provide friendship, which makes the mentee feel more like a peer and assists the mentee to get socialized into the organization. However, mentoring affects more than just the mentee. It also impacts the organization. Studies suggest that effective mentoring can:

14

QUALITY | April 2011

• • • •

Improve individual and organizational performance. Result in higher employee retention. Achieve higher promotion rates. Identify people with high potential more easily and earlier. • Maintain greater organizational loyalty. There are many mentoring techniques, but here are six that can positively influence the implementation of a mentoring program: 1. Legitimacy. Having a well-respected mentor in a relationship with an inexperienced quality professional lends credibility to the mentee. 2. Relevance. When a mentor sponsors a quality professional, he is showing that quality initiatives are valuable to the organization. 3. Protection. Quality initiatives typically require time before they can deliver significant results. Not all operational managers are patient and supportive with short-term results. Mentors can use their positional power to protect the mentee and quality initiatives from premature elimination. 4. Networking. Most initiatives come at a cost. Because a mentor tends to be well-connected within an organization, his network can become a resource for the mentee. 5. Soft skill development. Many quality professionals are well-trained in their technical field. However, successful quality professionals can simplify and communicate the numerical benefits of quality initiatives to others. Mentors can teach their mentees the importance of skills not well defined in textbooks, such as persuasion, reflective listening and consensus building. 6. Transference. Mentoring is a great way to leave a legacy. Mentors pass on knowledge and experience which is a win-win for the mentee and the organization. Continuous improvement is enhanced through the technical and the human side of quality. An excellent way to accomplish this improvement and ensure longer-term growth is through seasoned mentors who are willing to make a commitment in a caring way, which involves taking part in the learning process side-by-side with the mentee.

www.qualitymag.com

Designed with CAD. Inspected to CAD.

Multisensor Medical Component Inspection Systems 3D medical parts demand a 3D inspection solution. Brown & Sharpe, a brand of Hexagon Metrology, offers two complete multisensor product lines: Optiv vision-based systems, and Global bridge CMM systems. Both offer ideal capability for 3D dimensional inspection of orthopedic components, or any other medical component or device that has precise, complex 3D geometry. Both machines are Powered by PC-DMIS software, the leader in CAD based Optiv Multisensor Vision Systems

Global Multisensor CMM Systems

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dimensional inspection. Because parts designed in CAD should be inspected to CAD.

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OTHE R D I MENSI ONS

BY HIL L COX

Calibration Mistakes:

Plain Plug Gages No matter how careful we are at any given task, mistakes are often made; the calibration of gages and instruments is no exception. Hill Cox is president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

T

he simple appearance of a plain plug gage member can be quite deceiving when it is to be calibrated. Typically, it’s a diameter like many others we encounter, and the close tolerances they are made to appear to be the only element of concern. But there are other features that are part of them that can invalidate a calibration result if they are not detected or corrected for. Simplistically speaking, I’m referring to the geometry of the gage. The two most important elements that consistently pop up are roundness and taper. Size variations due to roundness are unlikely to be evident in a typical calibration setup while having a major role in the function of the gage. With the exception of ovality, a roundness analyzer is required to detect this condition. A good technician will notice the presence of taper from wear at the front of the gage or an overall condition due to its manufacture. For this to happen, several measurements for diameter have to be taken over the length of the gage, something that not every calibration facility does. A mistake often made in this regard is that it is assumed that as long as the measured sizes are within the diameter tolerance, the gage is acceptable. The standard for such gages is more specific in that geometric irregularities such as taper should not exceed half the diameter tolerance.

EQUIPMENT There are three basic types of instruments used for this type of calibration. The most common are a high magnification comparator—usually electronic, a bench micrometer or a universal length measuring machine designed for this type of work. All three contact the work with either small diameter anvils, or a contact point and large flat worktable on a comparator stand, or variations of them. Mistakes arise when the condition of the contact surfaces is not verified and one of the following situations has a direct affect on performance: • Flat contacts are not flat or parallel to each other • Comparator worktables are worn directly beneath the upper contact point • Contacts are misaligned or not square to the axis of the gage being measured

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QUALITY | April 2011

A mistake in selecting the contacts used can lead to significant errors. One of the more common errors is the use of regular micrometer-style contacts that cannot measure diameter at the end of the plug because of their large contact area. The mistake made here is where the end of the gage is contacted on the edge of the measuring faces rather than in their center on the axis of the instrument.

MASTERS Gage blocks are the usual masters for 1:1 comparative measurements, typically one build-up per size being measured. Often, they are carefully wrung together but the known size variations from their calibration report are not taken into account. Some skip this step and assume that the accuracy grade for the set is such that they don’t have to get that picky. The finer the tolerance, the greater the errors that will come out of such practices. One mistake often made is to ignore the effects of the wringing interval and the flatness and parallelism of the blocks which, when they are wrung together, increases their “size.” Some calibration facilities attempt to reduce costs by using long-range measuring heads on their comparator stands. Measuring ranges of 1 inch or 25 millimeters with a high-resolution display lead many to believe they can avoid wringing up gage block stacks. This works to a point but a mistake often made is the failure to confirm that the axis of the measuring head is square to the plane of the worktable. Errors in this alignment result in a cosine error that guarantees errors in the measurement. All calibration activities are subject to errors caused by temperature variations. Often this is due to the mistake of assuming that the general air temperature in the laboratory means everything in it is the same temperature. Excessive handling of the gage being measured or the gage block buildup creates the most problems. Keeping both on a normalizing plate as much as possible will reduce this problem. Adjustments to measuring heads on comparators can produce enough heat through friction that will cause problems. Make it a rule to allow time for these variations to dissipate before making a final setting on the display.

www.qualitymag.com

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Introducing EQUATOR™ —the revolutionary system that finally creates a solution between custom gauging and CMMs Nothing compares to Equator™ The new Renishaw Equator™ is a dramatic departure from the constraints of choosing either a custom gauging solution or a trip to the CMM. Experience up to 70% savings with significantly reduced fixture, installation and maintenance costs. Different parts, same Equator—never buy another custom gauge. Nothing compares like Equator™ N Highly repeatable master and measure technique (with thermal stability) extends CMM reach onto the shop-floor N

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Are you limited by time and budget constraints but hungry to hear from industry experts, view product demonstrations, take home whitepapers and case studies, network with peers and visit multiple suppliers all in one trip? We have the solution! On May 4, right from the comfort of your desk, you’ll be able do all this and more at Tech ManufactureXPO, THE virtual event for the manufacturing industry, bringing you trends in manufacturing from design to delivery. The team has been working hard and is pleased to announce that all educational sessions will be FREE to registrants.

What is a virtual event? A virtual event is a gathering of people sharing a common environment online to create an interactive experience similar to a conventional trade show. As an attendee, you can interact with booth personnel, network with peers, watch equipment video demonstrations and webinars and download product catalogs or other technical documents into your virtual trade show bag, just as you would at a conventional trade show. Since virtual trade shows can be attended by your entire team and be viewed from a single computer screen, cost of travel, lodging and time away from the office issues are essentially eliminated.

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LIVE webinars will be taking place all day in the Auditorium. After each webinar, you’ll be able to participate in an Ask the Expert chat with the presenter/s. A special Lunch-n-Learn session on Trends in Green Manufacturing will take place from 12:30-1pm ET in the Networking Lounge. All sessions are included with your FREE registration. 9:00- 9:45am ET Keynote Reshoring: A key to lower costs, more sales and a stronger economy Harry Moser, Founder and President of The Reshoring Initiative The Reshoring Initiative helps quantify the benefits of sourcing in the United States instead of offshore. To help companies make better sourcing decisions the Initiative, www.reshorenow.org, provides: software to calculate the real impact of offshoring on a manufacturer’s P&L, linked NTMA/PMA Purchasing Fairs to help companies find competitive U.S. sources, publicity to drive the reshoring trend, an online Library of 98 articles about successful reshorings and a 5-step process for focused regional reshoring programs. Benefits of attending include: 1. Free Total Cost of Ownership (TCO) software 2. Customers: learn how and why to calculate TCO 3. Suppliers: learn how to sell the benefits of local sourcing. SPONSORED BY

9:45-10:00am ET Ask the Expert: Harry Moser 10:00- 10:45am ET Automation: It’s not just for high volumes anymore Kurt Greissinger, Industry Manager- Assembly & Handling Kurt Greissinger, Industry Manager for Assembly Products at Bosch Rexroth, takes on some common myths about automation and lean, and uses a variety of examples drawn from real-world applications to prove that automation makes a vital contribution to lean manufacturing solutions. At a time when companies are tearing out conveyor systems in the name of lean, he will describe the roles automation can play and the benefits it offers across multiple applications. Through this webinar, engineers and systems designers will gain new insight into the nuances of human interaction with automation and key ergonomic considerations in automated and semi-automated processes. • The Role of Automation in a Lean Manufacturing Environment • Humans vs. Robots • Ergonomic Considerations for Assembly • Considerations for Manual vs. Automated Tasks

10:45-11:00am ET Ask the Expert: Kurt Greissinger 11:15- 12:00pm ET TBA Educational Topic 12:00-12:15pm ET Ask the Expert 12:30- 1:00pm ET Lunch-n-Learn: Trends in Green Manufacturing Manufacturers are increasingly looking at their operations with an eye toward sustainability. In this interactive session, manufacturing professionals can chat live with the editors of ASSEMBLY, Quality, Adhesives & Sealants Industry, CircuiTree and World Trade 100 about the latest trends in green manufacturing. Manufacturing professionals will learn about the latest ideas in environmentally friendly materials, design for the environment, landfill-free manufacturing, supply chain management and other topics. It’s also an opportunity for you to share what your company is doing to become more sustainable. No matter what your industry or company size, you won’t want to miss this session. 1:15- 2:00pm ET Lowering the Total Installed Cost of Assemblies in Today’s Manufacturing Environment Michael Poth, Director of Global Marketing, Stanley Assembly Technologies Emhart Teknologies delivers engineered fasteners and systems that provide solutions to an array of extremely complex fastening challenges customers face today. Through optimal engineering and design the webinar will show you how the Emhart Family of companies use varied techniques to lower the total installed costs of assemblies. 2:00- 2:15pm ET Ask the Expert: Michael Poth 2:30- 3:15pm ET Reverse Engineering Featuring Paul Jr. Designs Julius Ndulue, Applications Engineer, FARO Paul Jr. & Vinnie – Paul Jr. Designs The purpose of this webinar is to demonstrate how to use a portable coordinate measuring machine (CMM) for the reverse engineering of parts. Paul Jr. and Vinnie of Paul Jr. Designs will be sharing their experiences using a CMM and how it has improved their reverse engineering processes. 3:15- 3:30pm ET Ask the Expert: Julius Ndulue, Paul Jr. & Vinnie

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podcasts Listen to these 15-minute How-To Podcasts On-Demand all day!

Lean in Assembly Operations Lean expert Dan Fleming is Continuous Improvement Manager with the Greater Boston Manufacturing Partnership, a non-profit consultancy that helps businesses become more productive and competitive through lean practices. In this podcast, part of the popular Bosch Rexroth Lean Manufacturing Series, he discusses how, contrary to popular perception, automation technology and lean practices actually work well together in assembly operations. Dan explains that any assembly operation -- manual, semi-automated or fully automated -- can be wasteful and inefficient if poorly designed. He shows how lean can be designed into automation systems, to make them effective components of a fully lean manufacturing operation.

Selecting the Right Meter-Mix Dispensing Equipment Many factors need to be considered before the right meter-mix dispensing system can be selected for your adheisve or selant dispensing application. Sealant Equipment ensures the right machine is assembled by offering all eight (8) metering principles and selects the right model to match the process and application of material. We work with the customer and their suppliers to ensure the right components are selected for precision performance, quality products and lowest return on investment for the life of the system.

Testing Advances for 2011 This podcast will focus on applications in the medical device and automotive industries. They will demonstrate how state of the art technology in leak testing and functional testing help global manucturers improve quality and reduce costs to exceed customer expectations.

Measure Your Entire Process

Measurement, inspection and verifying that both parts and machine tools meet spec is critical to delivering product quality. Performing such tasks over long distances and with large parts is the done most effectively and accurately with a laser tracker and a variety of targets that expand a laser tracker’s capability. Measuring the machine tools that manufacture those parts is a critical aspect of ensuring part quality too, and not every technology supplier takes you through the whole process. Automated Precision Inc. will address the fundamentals of sound measurement and inspection, from the time you install your machine tool to before you cut the first part until you complete final assembly; and how laser-based, noncontact, optical inspection makes it all possible.

www.TechManufactureXPO.com

Product Reviews Get a sneak peek at products featured in the show!

I-360™ 2011

The Avinut™ Insert from Avdel®

Automated Precision Inc. now brings industry the I-360™ 2011 model. The newest iteration of both the wireless and the probe/scanning versions of the I-360™ have all the great features you need, while implementing a sleeker, more user-friendly design. The streamlined silhouette is easy to use, and more comfortable to hold. In addition, the new red color helps operators easily locate their I-360™ 2011 whether using it on the shop floor or in the field.

The Avinut™ Insert from Avdel® is a rapidly installed threadless insert utilising Speed Fastening® technology that mates with thread forming screws providing robust, reliable joints. Avinut™ is ideal for applications prone to screw cross-threading or painted assemblies because threads are formed by the screw, eliminating the need for costly secondary operations like thread masking for excess paint.

Automated Precision Inc. 15000 Johns Hopkins Drive Rockville, MD 20850 (240) 268-0400, [email protected] www.apisensor.com

Contact: Infastech™ Marketing Tel: 704 888 7039 E-mail: [email protected]

EcoShape: The Next Dimension in Tubular Framing

FARO Edge

Get the new shape of lean with Rexroth EcoShape Tubular Framing. Simple, versatile and efficient, EcoShape framing makes it easy to build custom workstations, material shuttles or flow racks. Create new solutions or extend existing ones using EcoShape’s advanced connection technology and full range of connectors.

As the industry leader, FARO once again raises the bar in portable measurement with the revolutionary FARO Edge – the most advanced state-of-the-art FaroArm® ever introduced.

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The FARO Edge’s industry-leading features make it the ideal tool for companies constrained by the limitations of fixed CMMs and lesser portable measurement arms. www.faro.com

Promess PRO Monitoring The Promess Mini-PRO Monitoring System is a stand alone process monitoring and test device. It is powerful yet simple to use making it perfect for monitoring assembly applications. The Mini-PRO system allows for the connection of a large range of sensors to monitor a variety of processes some of which include force, distance, torque, current, pressure, flow, etc. Promess Inc www.promessinc.com 810-229-9334

New Pneumatic Nutsetters offer improved Accuracy and Ergonomics The new AA series nutsetters from Stanley offer increased productivity in a new ergonomic and modular package. With a new clutch shut-off system, the AA series offers improved tightening accuracy from 4.5 to 118 Nm in multiple configurations while sharing heads and gearing with the QPM line of DC tooling. Schedule a demo today. For more Information call (877) 709-8007 or e-mail [email protected]

Exhibitor Directory

Chat with reps and experts LIVE during the show on May 4 from 8:30-3:30 p.m. EDT in the Exhibit Hall.

Custom Automated Test & Assembly Equipment www.automationtool.com Experience innovative measurement solutions from API with products such as laser trackers and accessories, measurement arms, and machine tool calibration products. www.apisensor.com O-ring, Seal, and Retaining Ring Installation Machines / Pad Printing Equipment www.asporing.com, www.padmark.com Visit our virtual booth to see all of our latest Robotic End-Effector products and developments. www.ati-ia.com www.infastech.com One of the world’s leading sensor manufacturers, providing innovative and practical sensing solutions for a wide range of applications and industries. www.balluff.com Radial riveting, Orbital riveting, press assembly equipment. Single station, semi-automated and automated workcells. www.baltecorporation.com The Drive and Control Company. World-class drive, motion and control technologies to power today’s most advanced manufacturing systems. www.boschrexroth-us.com Customized Automated Assembly and In-line Testing Machines for High-Volume Production www.bucci-industries.us COX is the leading manufacturer of quality caulk guns and epoxy applicators offering manual, pneumatic and battery powered variants. Made in the USA & UK! www.cox-applicators.com Affordable, scalable software solutions for calibration management, preventative maintenance and supplier QA. www.cybermetrics.com DELTA REGIS Tools Inc.

Delta Regis Tools, Inc. has been steadily growing for the last 15 years with a focus on Customer Service, Quality and Value. www.deltaregis.com Automatic Screw Feeding and Driving Systems www.designtoolinc.com FARO develops portable computer-aided coordinate measurement and imaging devices and software. www.faro.com Software that Enables Effortless Quality Management www.intelex.com World Leader in Test Technology www.intertechdevelopment.com New product presentation and introduction of the USA item distributors www.item24.com/en Logistick provides a variety of one-way, disposable freight securing devices for use in the transportation industry. www.logistick.com The Application Experts www.mahr.com www.motoman.com Origin/laser gauge logo LaserGauge: flexible, handheld laser-profiling system used for dimensional measurements and inspections. www.origintech.com A leading U.S. manufacturer of highly adaptive monitoring and motion control systems used around the world to assemble and test products. www.promessinc.com Your partner for Toolholding, Workholding and Automation Components www.us.schunk.com Dispensing Systems for Bonding, Sealing, Potting, Encapsulation, Casting, Gasketing, Lubrication and more. www.sealantequipment.com Automatic Ink Code-Marking Machinery for date, product, lot and spot ink marking impressions on a wide variety of surfaces. www.sprintermarking.com Complete product selection guides, information and specifications. www.emhartamericas.com A worldwide leader developing Inspiring Automation. www.weissna.com

w w w.Te c h M a n u f a c t u r e X P O . c o m

Q UA L I T Y 101

The Whys and Hows of

Flowcharting A flow chart should deliver instant knowledge relevant to what needs to be done at that moment, with complete reliability. BY BI L L BE S T

I

n the world of business, we all need to know what the sum of our efforts ultimately leads to. If we fail to understand this, our mental lives will be poorer, the results of our efforts will be substandard, and we will be inefficient operators—regardless of the very welcome pay check. Quality, along with profits, will most certainly suffer. Meetings are no substitute for progress; however, knowledge—which springs from communication—is the key to achievement. We are all managers, as well as workers. Many of us are limited to managing how we use our own time; others manage and shape the way our

whole business operates. The difference is in the detail of what information is needed to do the job and what one must impart to allow others to do theirs. The resulting knowledge base is the bedrock every company needs to prosper. If the business is to succeed, one must ensure that access to this knowledge is fast, simple, current and relevant. With this in mind, a flow chart is a great communication method. It is easy to interpret and it can be viewed by those who need it whenever they want. Developed in the right way—with good tools and in the right hands—flow charts will deliver much more than an

Figure 1: Start at the macro level by converting basic steps into a linear chart. Source: Proquis Inc.

illustration of the process. The flow chart should deliver instant knowledge relevant to what needs to be done at that moment, with complete reliability.

THREE BASIC STEPS A flow chart is a graphic representation of the successive steps in a process, procedure or system. It uses symbols interconnected with lines to illustrate three basic steps: input, operation and outcome. Mapping a process is actually quite simple, if done with the right tools. To make flow charts truly useful, create them with a systematic approach. Start at the macro level: Design, sell, make, deliver. These steps can be converted into a linear chart (see Figure 1). It is tempting to start creating flow charts at the micro level first, but be careful. Although it may seem to be a faster and more relevant approach, it can easily become a haphazard collection of unrelated charts that can lead to potentially serious inconsistencies and omissions. This is wasteful effort. After acquiring approval from top managers that this macro process meets the business objectives, focus on each step and then elaborate. In practical terms, this usually means sitting down with the manager to map the processes for which they are responsible. This again should be high-level. Some tools are quick—a chart can be created to explain the process, or records can be kept in note form. Take the following steps: • Receive order from sales or client. • Confirm specification. • Order components. • Allocate machine time. • Make product. • Final inspection. Rework if needed. • Dispatch. These notes can be automatically converted to another linear chart (see Figure 2). This is the second layer of activity under the ‘make’ step in the initial chart.

KEY OUTCOMES

Figure 2: The second layer of the chart begins at the ‘make’ step. Source: Proquis Inc.

www.qualitymag.com

One then repeats the activity, expanding each step by observing and talking to the people who carry out the work. One approach is observing and making simple notes, then bringing them into

April 2011 | QUALITY

23

FREE Webi na

ter N r ow!

Regis

Reducing Warranty Costs through Quantification of Machined Lead Angle and Surface Characteristics of Rotary Seals May 17, 2011 | 2pm EDT

The average automobile has over eighty dynamic seals that can fail at any given time. Failures attributed to leaking seals cost the transportation and power industry many tens of millions of dollars a year in warranty costs, recalls and fines. Advances in seal/shaft design and materials have extended the service life and reliability of vehicles and engineered systems. However, traditional measurement techniques are unable to keep pace with today’s smoother shafts and more rigorously controlled seal interfaces. Tighter specifications demand a more robust, gage-capable metrology solution that can quantitatively measure machined lead angles to zero degree tolerances as outlined in industry specifications, such as ISO 6194-1:2009 and RMA OS-1-1 rev. 2004, thereby improving production quality and enhancing manufacturing yield. This webinar describes a unique new metrology solution that accurately and repeatably measures all elements that contribute to the diminishing of a dynamic shaft seal by providing a true and precise profile of the shaft global lead angle. In addition to providing a quantitative analysis of lead angle, the metrology system simultaneously measures surface roughness parameters, such as Ra, allowing manufacturers for the first time to obtain an accurate measurement profile of dynamic sealing systems while improving manufacturing throughput and yield.

M o d e rator

Speakers

Gillian Campbell

Andrew Masters

Erik Novak

Editor Quality Magazine

Vice President, Strategic Marketing and Business Development Bruker Nano Surfaces Business

Director, Technology Development Bruker Nano Surfaces Business

Brought to you by

Register for FREE at webinars.qualitymag.com! Can’t attend live? Register to receive the on-demand version.

|

QUA LIT Y 101

|

a room and showing others the first draft. If the changes can be quickly displayed and made while others talk— as some tools are adapted to do—the review of the chart is fast. Making the changes as the staff discusses will often provide a lot more detail about the real process, some of it often unexpected. There are four key outcomes from this process: • Staff will have found great ways to work efficiently around inefficient processes. • Staff gets an early warning of unacceptable shortcuts and previously unidentified risks. • Everyone feels they are part of the process and owns a piece of it. • Increased engagement leads to improvements in all areas: quality, efficiency and customer delight.

nism of change control, signoff by managers and an archive of past versions. Being able to trace back to a process in operation at the time of nonconformances makes investigation much easier. Some systems also have the ability to analyze and simulate a process activity

in simple terms, but flowcharting software that provides for these analysis are ideal for moving toward Six Sigma. Bill Best is president of Proquis Inc. (Schaumburg, IL). For more information, e-mail [email protected] or visit www.proquis.com.

After the processes are produced for all the layers of the business, the bottom layer will provide a task-by-task operational instruction flow chart, allowing staff to carry out the most tasks, or at least have a detailed understanding of how such tasks should be done. A good flow chart is: • Fast to produce and amend. • Capable of connecting steps to more detail or data, other documents, applications and Web services. • Easy to understand and walk through logically. Having created this hierarchy of processes, it is important to have a mecha-

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April 2011 | QUALITY

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QUA L I TY I N NOVAT I ONS

The HPX-1 diagnostic system employs a patented phantom and an automated tool to perform a variety of tests on the HPX-1 computed radiography reader, characterizing and monitoring key imaging performance parameters. Source: Carestream Health Inc.

Total

Quality Tool What makes the HPX-1 diagnostic tool unique among modern process monitoring tools is its automated nature. BY KA RI O ’RO URKE, MA NAGI NG E DI TOR

A

s digital radiography becomes more prominent in the nondestructive testing (NDT) industry, there is a growing concern among companies to monitor the performance and stability of their imaging systems. In some cases, system monitoring is required, but for other companies it is out of the need to protect their investment and be proactive. By using a diagnostic tool, companies may be able to spot a trend toward performance degradation before it becomes a real problem, or before it becomes apparent in their routine or production images. Even before one of the parameters goes out of spec, they would be alerted that it might be almost time for a recalibration or routine service. To keep up with this demand,

Carestream Health (Rochester, NY) has designed the HPX-1 diagnostic system that employs a patented phantom and an automated tool to perform a variety of tests on the HPX-1 computed radiography (CR) reader, characterizing and monitoring key imaging performance parameters. Currently, there are a variety of phantoms being used for performance monitoring, but what makes the HPX-1 diagnostic tool unique is its automated nature. It eliminates subjective judgment and tedious analysis for the operator and provides speed, objectivity and accuracy. “As more operators adopt digital radiography (DR), they are naturally concerned with getting the optimal performance from their imaging sys-

tems. Many industry prime contractors that require critical inspections also require their contractors to certify and document the performance and stability of their imaging systems,” says Steve Mango, worldwide technical manager at Carestream Health. “Operators need to do this in the most accurate and efficient manner possible, with minimal impact on workflow. While such automated systems exist in the medical field, they have not been available to the NDT industry until now.” The system has an interface that allows the operator to scan an exposed imaging plate and obtain an immediate reading on the health of the system with status lights for each of the system tests. The calculations are then evaluated against a table of projected results and tolerances, and if the results are “good to go,” then a green light is triggered. An amber light is set off when results are approaching the limit, and a red light indicates when the system needs to be recalibrated or serviced. A ready indication lets the operator know that the test is ready to go but has not yet been completed. “The analysis is all automated, so the operator need not to be a scientist and does not need to understand the intricacies of modulation transfer function or detective quantum efficiency. Any operator who can manage a CR system can use this tool,” says Mango. When an image is scanned at a particular pixel pitch, the apertures are imaged at precise locations relative to each other. The software then analyzes the data to locate transitions in pixel values to precisely locate each

SPECIFICATIONS  A simple phantom for monitoring digital imaging system performance is employed.  The software can precisely locate the position of each aperture.

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 The precise locations of the reference markers (apertures) are used to compute a variety of geometric parameters; in this example, pixel aspect ratios.

 The system stores all test results for the past year, which can be reviewed individually or collectively, in logs, tables or graphs.

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of the apertures. Using the location of the apertures in the phantom, the tool calculates a variety of parameters relating to geometric accuracy, such as pixel size in both fast and slow scan directions, pixel aspect ratio, scan nonlinearities and pixel placement error. At the ASNT show last fall, the HPX-1 diagnostic tool was met with overwhelming response. According to Mango, show attendees indicated it would inspire confidence in their examination results, improve their workflow, and generally make their jobs easier and more cost efficient. The monitoring system was released this past February. It is ideal for critical applications such as aerospace, petrochemical, power generation, nuclear and wherever certification or documentation of imaging system performance is required or desired. Although the technology is designed specifically for the HPX-1 digital system released last year, the basic philosophy also can be applied to any CR or DR system. For more information, contact: Carestream Health Inc. 1049 West Ridge Rd. Rochester, NY 14615 (585) 627-6726 [email protected]

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April 2011 | QUALITY

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50 Y e ar s of Qualit y With the ability to trace surface texture came the realization that, within the limitations of a probe or stylus tip and the device used, any part trace would include an amalgam of a nearly infinite number of different frequencies present in the path being traced. These, in turn, reflected characteristics imposed by the manufacturing process. This led in the early 1960s to the development of 2RC filters, a growing number of commercial instruments, and the popularity of basic roughness parameters such as Ra, Rq and Rz. Source: Mahr

even on a highly polished surface, is a microscopic maze of etchings that, if properly read, detail the history of a part’s manufacture. Developing the ability to properly read surface characteristics has been the challenge of metrologists and gage manufacturers for nearly a century, a challenge that continues today.

said to have postulated several rules for the behavior of sliding surfaces under load in his notebooks, which are often credited as the principle influence on the “laws of friction” published by French physicist Guillaume Amontons in 1699 and verified by Charles-Augustin de Coulomb in 1781. These early pioneers in the study of friction did not yet have the means to quantify the characteristics of the surfaces in order to understand the role that the microscopic structures on the surfaces played in the functional characteristics. But it was the industrial revolution that really sparked the need for a means to measure surface texture and accurately quantify it. The earliest surface measurement devices were reference surfaces machined to various degrees of roughness. Machinists would literally scratch the surface of their parts with their thumbnail and compare them with the reference. Using this method, a good operator could replicate surface finish reasonably well, but the process was a simple go/no-go procedure. No data was gathered and no mathematical analysis conducted. In addition, since there was no means of actually quantifying a surface, the standards themselves were subjective.

EARLY HISTORY

EARLY GAGES

Leonardo da Vinci is credited by some historians with being the father of modern tribology—the science and technology of friction, lubrication and wear. Among his myriad interests, he studied friction, wear, bearing materials, lubrication systems, gears and rolling-element bearings. He is even

For many years, engineers naively believed that smoother was better. Several events changed this view, one very dramatically. It happened in 1930 when Bentley engines, which were manufactured with exceptionally smooth cylinder walls, seized up during the Le Mans 24-hour race.

A Superficial History of

Surface Finish Any number of influences can leave their mark on the surface of a part. The result is a microscopic maze of etchings that detail the history of a part’s manufacture. BY PATRICK N UGEN T

E

ngineered surfaces need specific characteristics in order to perform as desired. Surface measurement evaluates those characteristics and helps control the manufacturing processes to ensure that the surface will function as desired. It is said that the “height of superficiality” is to look only at the surface of something. Yet, the topography of an engineered surface can get surprisingly complex. Any number of influences can leave their mark on the surface of a part, from the cutting tools and abrasives that finish it, to the chucks and fixtures that hold it, the machine tools that spin and shape it, and even to things such as vibrations from nearby machines or processes. The result,

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The digital revolution allowed us to create instruments that digitize the analog signal from the stylus and generate the typical surface profile trace we are familiar with today. With the profile in hand it became possible to apply mathematical tools to analyze a wide variety of profile characteristics. Today there are literally hundreds of different ways to analyze surface characteristics. Source: Mahr

There followed a concerted effort to better understand the role of surface texture and to quantify it in ways that were meaningful to manufacturing. Initially, optical microscopes were employed to provide a magnified view of surface characteristics. Again, measurement was comparative and somewhat subjective, but the various degrees of magnification and the differing fields of view afforded led to the concept of sampling lengths and frequency that are central to surface analysis today. Other early efforts to capture information about a surface utilized a trace stylus and a mechanical “amplifier” which used linkage to replicate the trace onto a smoked glass surface. In 1933, E. J. Abbot developed what is widely believed to have been the first analog surface instrument. This used a stylus to contact the part and provided an actual number to quantify texture. Abbot also co-developed the Abbot-Firestone curve. This used a simple curve to represent the surface and made contact area the basis of the curve, allowing the calculation of a material-to-air ratio as a function of depth. This was the first instrument to

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With today’s digital surface instruments, analysis of 2-D digital profiles has gone way beyond simple mathematical averages. It is now possible to compute sophisticated functional characteristics, such as the ability of surfaces to bear loads, retain lubrication, seal against leaks, and even support the growth and attachment of human bone. Source: Mahr

link form with function in a numerical manner simple enough to quantify a surface and help control manufacturing processes.

MODERN INSTRUMENTS With the ability to trace surface texture came the realization that, within the limitations of a probe or stylus tip and the device used, any part trace would include an amalgam of a nearly infinite number of different

frequencies present in the path being traced. These, in turn, ref lected characteristics imposed by the manufacturing process. Just how to segment and analyze this data occasioned much theoretical work during the next decades. This led in the early 1960s to the development of 2RC filters, a growing number of commercial instruments, and the popularity of basic roughness parameters such as Ra, Rq and Rz.

In 1933, E. J. Abbot developed what is widely believed to have been the first analog surface instrument which used a stylus to contact the part and provided an actual number to quantify texture. He also co-developed the Abbot-Firestone curve. This uses a simple curve to represent the surface and make the contact area the basis of the curve, allowing the calculation of a material-to-air ratio as a function of depth. This was the first instrument to link form with function in a numerical manner simple enough to quantify a surface and help control manufacturing processes. Source: Mahr

April 2011 | QUALITY

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5 0 Y EA R S O F Q UALI T Y

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The single largest event to change how surfaces are measured was yet to come however. The digital revolution allowed us to create instruments that digitize the analog signal from the stylus, and generate the typical surface profile trace we are familiar with today. With the profile in hand it became possible to apply mathematical tools to analyze a variety of profile characteristics. Today there are literally hundreds of different ways to analyze surface characteristics, some codified into national and international standards, others specific to various industries or even individual companies. Moreover, analysis of two-dimensional (2-D) digital profiles has gone way beyond simple mathematical averages, and it is now possible to compute sophisticated functional characteristics, such as the ability of surfaces to bear loads, retain lubrication, seal against leaks, and even support the growth and attachment of human bone. Digitization also is blurring the lines between what was once considered surface measurement and part geometry. Metrologists today often categorize the data from a measured surface into three categories—roughness, waviness and form. Shorter wavelength data tends to reflect surface roughness characteristics imposed by machining operations, such as turning, grinding or polishing. Waviness involves longer wavelength data and might reflect instabilities in the machining process, such as imbalance in a grinding wheel or worn spindle bearings. Long wavelength data tends to reflect errors, such as lack of straightness in the guideways of a machine or misalignment of machine axes. These long wavelength errors are usually thought of as form characteristics, such as roundness, straightness or flatness. Perfect straightness, for example, could be described as a line, or wave, with an amplitude of zero. Furthermore, what is perceived as a short wavelength and what is a long wavelength are now generally understood to vary depending on the size of the part and the intended function of the surface. In addition, while old analog instruments gathered only the data needed for a specific measurement, modern digital instruments gather a whole

spectrum of data from each trace, making subsequent analysis of other wavelengths possible without the need to remeasure the part.

FUTURE DIMENSIONS As dimensional tolerances have grown steadily tighter over the years, and the need for documentation and traceability become ever greater, the role of surface finish measurement in the manufacturing process has grown dramatically. It has been estimated that in the 1940s, the proportion of the tolerance band taken up by surface irregularities was roughly 15%. Today that proportion is sometimes 50% or more for precision components. Future developments in surface metrology will no doubt make the process even more important. As microprocessors gain power and the ability to process enormous amounts of data becomes economically feasible, optical systems are coming back into vogue and opening up new avenues of exploration. With optical systems there is the opportunity to measure a surface in three-dimensional (3-D) rather than the typical 2-D measurements made with stylus tracing instruments. It is generally believed that since surfaces exist in 3-D and function in 3-D, measurement of these surfaces using 3-D instrumentation should allow better linkage between the measurements and the suitability of a surface to perform a desired function. But there is a great deal of work still to be done before this becomes part of the typical surface measurement specification. Currently there is a lot of research being done with various optical techniques, and it is clear that different technologies measuring the same surface sometimes “see” different things in the structure of the surface. Work to create standardized measurement and analysis methods for these optically measured surfaces is critical to lay the groundwork for the use of 3-D parameters. So there is more to come on how to properly read a surface, but we are standing on the threshold of the next revolution. Patrick Nugent is vice president of metrology systems at Mahr Federal Inc. (Providence, RI). For more information, e-mail [email protected] or visit www.mahr.com.

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QUA LIT Y ME A SUREM EN T

| Participants in the study were provided with equipment including digital micrometers, digital calipers, gage blocks and paper towels. They were also given workpieces consisting of a short pin, a long pin with a threaded hole and a sleeve. Source: MultiMetrics Inc.

WHEN IT COMES TO MEASURING,

FIRST THINGS FIRST T

oday’s ever-expanding repertoire of metrology applications—and the frequency with which they are employed—is outstripping the supply of “gray beard” measurement specialists who have the experience to set up and execute them. The field of large volume, portable 3-D metrology is no exception, where for the past decade, development of technologies, such as laser scanners and trackers, electronic theolodites, photo- and videogrammetry, articulated arms and enhanced coordinate measuring machines (CMMs) have been enabling accurate measurement of large-scale volumes. These systems can measure the volumetric features of vehicle interiors and exteriors, aircraft or naval structures, buildings and even whole environments. Typically, the data is used for quality control, reverse engineering and rapid manufacturing routines. The latest technologies offer fast data capture and surprising accuracy, which, even when measuring on a scale of tens-of-meters, can be as accurate as ± 0.001 inch over distances of 100 feet.

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Whether measuring with calipers—or large-volume scanners—basic knowledge of dimensional metrology first principles enables better results. B Y MI C H AE L L . RYAN With the application of these systems exceeding the availability of experienced metrology specialists to run them, it is now common to see technicians who are classified as machinists, manufacturing cell operators, tooling people, and the like tackling 3-D metrology tasks. This situation is eased somewhat by the fact that these measurement systems typically incorporate powerful enabling software. This software makes it relatively easy for even inexperienced operators to set up and obtain measurements.

A DOUBLE-EDGED SWORD However, industry is finding that these enabling solutions can be a double-edged sword. That is because the programs generally have limitations, sometimes known, but often unknown to nonmetrology specialists operating them. The problem is that in order to obtain accurate results, a measuring routine

must be planned and set up in accordance with good/best practice before the measuring device is even powered up. And doing so requires an understanding of the axiomatic, self-evident “first principles” of dimensional metrology. These principles have to do with accounting for environmental effects such as temperature variations, cleanliness of measured surfaces, instrument cleanliness, stability of the instrument’s measurement platform and any remote components and instrument wear. First principles also include traceability of the equipment’s deviation from known standards of measurement and the subsequent need for calibration. Finally, first principles address the variation introduced by individuals’ differing behavioral approaches to taking measurements. While these factors apply to every type of dimensional metrology regardless of the equipment used—from

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Pin Gage, Day One

Pin Gage, Day Two

The part was a standard pin gage that is used to size holes. Values ranged from a low of 12.523 millimeters to a high of 12.714 millimeters, with a range of 0.191 millimeter. The histogram shows the amount of variation and also indicates more measurements went to the higher values rather than lower, for example, it was weighted to the high side. Source: Mitutoyo

The part was the same standard pin gage used in day one. Values ranged from a low of 12.689 millimeters to a high of 12.699 millimeters with a range of 0.010 millimeter. This is a reasonably good indication of consistency considering the environment and “informality” of the study. Day one had a range of 0.191 millimeter while day two had 0.010 millimeter. That is a very significant difference and demonstrates consistency that results from correct procedure. Source: Mitutoyo

Pin Gage with Threaded Hole, Day One

Pin Gage with Threaded Hole, Day Two

The pin gage with threaded hole is manufactured to have a tri-lobe on it that is offset on each end; this is done to demonstrate the difficulty in measuring a round part. The values on this measurement (performed without detailed instructions) had a low of 12.542 millimeters and a high of 12.701 millimeters for a range of 0.159 millimeter. As with the pin gage, this histogram also shows values weighted to the high side of the chart. Source: Mitutoyo

The part was the same pin gage with threaded hole used in day one. Values ranged from a low of 12.547 millimeters to a high of 12.565 millimeters, with a range of 0.020 millimeter. This is a pretty good indication of consistency considering environment and study informality. Day one had a range of 0.159 millimeter while day two had just 0.020 millimeter. That is a major difference and shows the consistency resulting from correct procedure. Source: Mitutoyo

gage blocks to the most sophisticated systems—in some respects, they are amplified in the application of 3-D measuring. That is because together with the expanded scale of the workpieces comes an expanded degree of freedom with respect to setup. And with that freedom come many more variables—and the opportunity to lose control. The somewhat problematic measurement performance stemming from this situation—and resulting quality/ productivity issues—have become a concern for operators of 3-D metrology systems, not the least with manufacturers of the equipment. It was in this context that leading manufacturers approached

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the Coordinate Metrology Society (CMS) looking for help and guidance.

LOOKING FOR GUIDANCE The CMS is a group of users, service providers and OEM manufacturers of close-tolerance, portable, industrial coordinate measurement systems, software and peripherals. The CMS hosts an annual Coordinate Metrology Systems Conference (CMSC). This is a venue where the latest in portable 3-D industrial measurement technologies is presented by industry experts via a large slate of technical paper presentations, exhibits, seminars and advanced workshops.

According to Talion Edwards, Boeing associate technical fellow and CMS chairman, “Users of 3-D measurement were telling us that they needed a centralized examination process that empowered a third party to certify whether a person possessed a practical body of knowledge regarding operation of 3-D measuring systems. Dovetailing with that, users were also asking whether the CMS could help in defining the matching training curriculum.” As it happened, in early 2010, Edwards had participated in a program addressing training of “First Principles of Metrology” presented by the UK’s National Physical Laboratory

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(NPL). The NPL is the UK’s National Measurement Institute—government owned and contractor operated—and equivalent to the United State’s NIST. Edwards elaborates, “The NPL sessions were especially relevant because they targeted nonmetrology specialists who were required to conduct high-level measurement tasks. Instruction and exercises using the simplest measurement tools, such as gage blocks and calipers, demonstrated

dramatic improvement in subjects’ capabilities as reflected in improved gage R&R (gage repeatability and reproducibility) results. It occurred to me that it would be of great value to demonstrate this phenomenon to the community of portable 3-D metrology. And it seemed especially relevant since the NPL was seeking to develop a large-volume metrology module.” Edwards contacted Keith Bevan, NPL training product development, to

see whether NPL’s “First Principles of Metrology” training could be adapted for a workshop at the July 2010 CMSC Conference in Reno, NV. Since NPL had no physical presence in the United States, Bevan called on his relationship with Mitutoyo America (Aurora, IL) to see if that company, with its metrology training operations, would be interested in having a hand in the CMSC project. As a result, a collaborative effort among CMS, NPL and Mitutoyo was born with Mitutoyo sponsoring the workshop.

WORKSHOP/STUDY The workshop was conceived as an experiment. Participants would make measurements and in the process generate data to support a hypothesis that, “Training in core principles of metrology will reduce or minimize variation of measurement.” The methodology was loosely inspired by a formal gage R&R. But instead of determining variation among tools or workpieces or individuals, the idea was to show how measurement behavior—that is, how methods, procedures, approaches and assumptions—varied between those individuals who received instruction and those who did not. Participants joined the study randomly as they came out of other CMSC presentations, talks and seminars. They represented the aerospace, nuclear, automotive, scientific and woodworking industries. Job titles included quality, scientist, management and metrology, with experience ranging from newly hired to in excess of 15 years.

METROTOM. We call it a CMM with an x-ray sensor. Metrotomography, the fusion of metrology and tomography, lets you non-destructively validate difficult interior and exterior GD&T dimensions. Both the METROTOM 800 and 1500 are traceable, calibrated gages. These systems are ideally suited in R&D, mold setup and ongoing quality control. They can also be used for assembly verification, void analysis, wall thickness analysis and reverse engineering. www.zeiss.com/METROTOM

Carl Zeiss Industrial Metrology (800) 327-9735 www.zeiss.com/metrology

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• Day One, Behavior with Minimal Instruction Upon entering the exhibit, participants were informed of the study’s two-day structure with results presented on day three. Day one participants were encouraged to participate on day two. Participants were provided with equipment including digital micrometers, digital calipers, gage blocks and paper towels. They also were given workpieces consisting of a a short pin, a long pin with a threaded hole and a sleeve. One of the pins had distortions not apparent to the eye; it was tri-lobed and twisted with a 60-degree offset end-to-end. After using a caliper to measure the inside diameter of the sleeve and the outside diameters of the two pins, it appeared that the

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short pin, 0.4995 inch, would barely fit inside the sleeve, 0.4995 inch, and that the long pin, 0.4945 inch, would fit easily. In fact, the short pin fit easily and long pin would not go in at all, due to the undetected lobes. Mitutoyo’s U-Wave system wirelessly linked the digital instruments to a PC for data capture via Mitutoyo’s MeasurLink software. The software would later be used to facilitate analysis and charting. According to Bevan, “Almost 100 subjects participated on day one. We provided minimal information, saying, ‘Please take these measurements for us…here are the instruments and supplies…here are the workpieces.’ Behaviors were quite mixed. For example, some, but not most, of the participants rolled the pin on the table noticing, ‘This is not round.’ Similarly there were various behaviors with respect to checking instruments against gage blocks and cleaning instruments and workpieces.” It was explained that questions asked by participants would be answered but that information would not be volunteered. In any case questions were rare. • Day Two, Behavior with Instruction On day two, participants (approximately 39, including the return of some day one participants) were provided with instruments, supplies and workpieces as per day one. In addition, they were given what amounted to a work order. The order sequenced tasks to guide the measurement practitioner in application of first principles/ good/best practices, for example, clean the equipment; check equipment for damage; ascertain equipment calibration status by checking against known artifact and measure these positions on the workpieces. Correct measurement behaviors were built into the procedure. Again, data was captured via Mitutoyo’s MeasurLink software. • Day Three, Results Presentation Study results were presented to all participants on the afternoon of the last day of the conference. Histograms of day one and day two measurements were generated and prepared as a PowerPoint. The study validated the hypothe-

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sis: a large variation in measured values was seen on day one, a much smaller variation was seen on day two. Edwards concludes, “The results were extremely promising. It is evident that even a basic application of dimensional metrology first principles enables much improved measurement performance— and this should apply to portable 3-D measurement systems as much as to hand

tools. We’re working on demonstrating just that by organizing a follow-on study at CMSC 2011 focusing on large volume measurement systems such as laser trackers or articulated measuring arms.” Q Michael L. Ryan is responsible for the MeasurLink and data management products at Mitutoyo America Corp. (Aurora, IL). For more information, call (630) 820-9666, e-mail mike. [email protected] or visit www.mitutoyo.com.

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Strength in Numbers D

eveloped more than 60 years ago out of necessity to measure precision components in the military, the coordinate measuring machine (CMM) has undergone several facelifts since its inception. Its first big transition was the shift from two to three axes, followed by the introduction of computer control. Nowadays, these machines are available in a number of different configurations, such as portable, benchtop, handheld and freestanding versions. Just as the sizes and shapes of CMMs have evolved over time, so have the

Digiti i g ttestt samples Digitizing l allows ll ffor measureable bl improvements in process, productivity and quality. BY K A RI O’RO U R K E , MAN AG I N G E D I TO R

inspection methods used with these machines. Conventional touch probes that are mechanically moved are still regarded as highly accurate; however, emerging trends in scanning technology—probes that drag along the surface of the manufactured part to collect points—are progressing rather quickly.

An example of this would be laser scanning, in which a laser line is projected over the surface to collect threedimensional (3-D) data points that are then reflected to a vision sensor mounted in the scanner. The technology is similar to that of a paintbrush dipped in paint and being dragged across the part.

TECH TIPS  The core of the inspection with laser scanning is the color map.

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 A laser line is projected over the surface to collect 3-D data points that are reflected to a vision sensor that is mounted in the scanner.

 Making sure the equipment is properly calibrated greatly reduces noise and other performance degradation factors.

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 A laser line is projected over the surface to collect 3-D data points that are reflected to a vision sensor that is mounted in the scanner. Source: Carl Zeiss Industrial Metrology

These data points are then transferred to a computer-aided design (CAD) program that works to create a 3-D replica of the physical part. A color map of the point cloud data overlaid on the CAD model shows geometry deviation in different colors across the entire surface of the part. This helps alleviate measurement time because after the inspector has the entire digital model of the part, there is no need to go back and scan other surface points. A go/no-go result is given and the data is stored for future use if further inspection is required later down the line. This saves the machine operator time and money while gaining flexibility to run a more detailed inspection on the digital copy without having to have the test part present. “The core of the inspection with laser scanning is the color map,” says Jay Elepano, business development manager, Nikon Metrology (Brighton, MI). “It is a very simplified report. If machine operators want to reverse engineer, it is important to understand what the part is. If it is a plastic injection mold that may have curves, and there are no prismatic features, maybe the operator just wants to make a freemarker template file—that is called a dumb model. There are very simple packages that do that. In addition, there is the ability to create a prismatic part drawing CAD rendering.” Elepano uses the example of a birthday cake with candles on it in a circle. If an analog scan is taken of this shape, how would the machine operator know if it is a birthday cake with a bunch of candles on it or if it is a car rotor with studs sticking out of it? The rough general shape of each is the same. Other advantages, according to Eric Hollenbeck, business manager North America, portable products, Hexagon Metrology (North Kingstown, RI) include instant graphical feedback. “This is extremely valuable, particularly in the early stages of production to verify the component is being manufactured correctly,” says Hollenbeck. “It also is useful in mature products so that a problem can be identified early,

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When it comes to more complex surfaces that have holes and slots, a cross scanner is the best solution since it eliminates the use of both a laser scan and touch probe. Source: Nikon Metrology Inc.

before shipments are made to customers with faulty, out-of-tolerance parts.”

INNOVATION When it comes to metrology, there is an increasing need for higher quality inspections at faster turn-around times. To help achieve this and reduce CMM inspection time, laser scanning is often a preferred method. While physical inspection is still highly accurate because optics are not weighed into the equation, it can be tedious and there may not be enough data present. In addition, there are limitations when it comes to freeform components and soft or fragile parts, which present the potential for the probe to collide with the part or CMM. Shrinkage and spring back are other issues that may affect quality inspections.

Orlando Perez, director of product management, Faro (Lake Mary, FL), adds that there is a huge momentum in the industry moving toward scanning and noncontact inspection. More and more manufacturers want to use this technology to speed up their processes. Faster capture rates for increased speed, higher density point clouds to capture greater detail are some of the emerging and evolving trends. From the software side, 64-bit computing to boost efficiency, automatic feature recognition and real-time comparisons between the captured scan data and the design intent are becoming more popular. Pearson says that the inspection method has evolved from a relatively simple diode laser sensor (DTS), which functions as a noncontact touch trigger probe, to the long trace profiler

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From the software side, 64-bit computing to boost efficiency, automatic feature recognition and real-time comparisons between the captured scan data and the design intent are becoming more popular. Source: Nikon Metrology Inc.

As newer innovations with software and laser scanning are released to the market, the design-to-manufacturing process has become more simplified and flexible for the technician. Source: Nikon Metrology Inc.

(LTP)–a scanning triangulation-based laser–to the scanning laser line sensor, which has three axes of rotation at the sensor. This is ideal for the complex geometries encountered in the automotive industry. An example would be gap and flush inspection between the doors and bodies of assembled cars. This determines a vehicle’s overall fuel efficiency and aerodynamic performance. Using a laser scanner, the inspector can digitize the entire spine that falls between the hood and front fender. As newer innovations with software and laser scanning are released to the market, the design-to-manufacturing process has become more simplified and flexible for the technician. “One of the most exciting things happening now in software is point cloud feature extraction,” says Hollenbeck. “Instead of a technician scanning a part and then manually defining features from the point cloud, software can automatically recognize features, such

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as hole slots and edges, which makes the process of detailed, feature-based inspection much more automated.” “Manufacturing quality is improved by giving the operator the ability to gather and evaluate more data in a shorter period of time, which translates to a more thorough inspection and corresponding tighter control over process variation,” says John Pearson, technical sales engineer, Carl Zeiss Industrial Metrology (Maple Grove, MN).

CRITICAL FACTORS When machine operators choose to 3-D scan a part, they should first ask themselves, “What do I want to do with the data?” For example, a car door has to fit together perfectly. They might want to inspect it for surface irregularities or compare it to CAD model. Another person might want to reverse engineer it. For freeform shapes, single laser scanners are ideal since they are fast and accurate and are often the choice

for retrofits. When it comes to more complex surfaces that have holes and slots, a cross scanner is the best solution since it eliminates the use of both a laser scan and touch probe. Another critical factor is setup. According to Perez, proper setup is important in any digital imaging process. Making sure the equipment is properly calibrated greatly reduces noise and other performance degradation factors. Glossy or shiny surfaces and darker colors are always challenging, regardless of the device being used so machine operators can always expect that the best quality scans will be achieved when capturing light color objects with dull or matte finishes. Although traditional touch probes on CMMs remain the standard in metrology because of their high accuracy, there is no getting around the time-consuming inspection process and limited ability to scan freeform applications. For the aerospace and automotive industries, the use of 3-D laser scanning has alleviated these constraints by allowing operators to have a complete inspection of large-scale projects in a matter of minutes. Q

QUALITY ONLINE For more information on digital inspection, visit www.qualitymag.com to read the following articles: • ”3-D Laser Scanning Accelerates Inspection” • “Replace Film with Digital Radiography” • ”Take a Closer Look at Laser Scanning”

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APRIL 11-13, 2011 CHARLOTTE, NC In Collaboration With:

Thank You Conference Sponsors & Presenters!

PRESENTERS

SPONSORS

This event wouldn’t have been possible without your support

• Henry Alexander Perry Johnson Laboratory Accreditation Inc. • Jeff Bibee Werth, Inc. • Forrest Breyfogle Smarter Solutions Inc. • James Drago Garlock Sealing Technologies • Neil Ducoff Strategies Publishing Group Inc. • Praveen Gupta Accelper Consulting • David Harris Glastonbury Southern Gage • Paul Hogendoorn OES Inc. • Tyrance Jackson AcousticEye

• Joe Jessop Criterion NDT • Paul Joss Perceptron • Paul Lomax Fischer Technology • Stephanie Masse Jesse Garant & Associates • Dave Maxham Automated Precision Inc. • Walter McGee Raytheon Space & Airborne Systems • Alan Metzel Northrop Grumman • Jeffrey Noruk Servo Robot Corp • Patrick H. Nugent Mahr Federal Inc.

• Paulo Pereira Caterpillar Inc. • Andrew Ramsey Nikon Metrology Inc. • Rick Richardson QA Productivity Systems • Jim Salsbury Mitutoyo America Corp. • Rick Sloop InfinityQS International • Harry Spinks Boston Scientific • Narayan Subramaniam Cognex Corp. • Mike McCurry Daimler Trucks North America • Shane Woody InSituTec

W W W. Q U A L I T Y M A G C O N F E R E N C E . C O M

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QUA LIT Y SOF T WA RE & A N A LY S I S

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Is Your

Process Performing? O

ne of the real treats of working in a statistical process control (SPC) software company is the exposure to a wide range of SPC applications. The use of process performance and capability indices is a consistently top-ranking concern for our clientbase, which extends globally across tens of thousands of clients in all types of industries. While I’ve enjoyed discussing these issues with so many clients over the years, in detailed training sessions or simply in response to their technical support queries, I feel at times the bearer of some rather unfortunate news: Most process performance estimates (and some process capability estimates) are essentially useless to your customers. They provide no indication of your process’s ability to meet requirements over the long term; they provide no comfort regarding a given shipment’s conformance to requirement. If your suppliers currently provide these estimates, demand either 100% inspection (for example, a measured value for each and every item shipped), or evidence of process control and its corresponding capability estimate. To understand the reasoning behind the use of process performance, a quick review of the indices is warranted. The calculations typically used are:

Discover the most common SPC errors and learn how to correct them. B Y PAU L K E L L E R

where USL is the upper specification limit (for example, the largest acceptable value for any unit); LSL is the lower specification limit (for example, the smallest acceptable value for any unit); x is the process average, sometimes referred to as x double-bar; ␴sample is the sample standard deviation; and ␴process is the process standard deviation. Note the only mathematical difference between the two process capability indices and their corresponding performance indices is the use of process sigma in place of sample sigma. Sample sigma is the standard deviation of a sample such as calculated by a handheld calculator or Excel’s STDEV function; process sigma is the standard deviation of the process, calculated using a control chart.

Error: Using sample sigma for process capability index. Proper approach: Use process sigma for process capability estimate.

 A process and its statistics are only predictable if the process is stable; an unstable process is chaotic and unpredictable.

 Once statistical control is established, a meaningful statistical distribution may be fit using SPC software.

Figure 1 contains an example control chart, the classic Shewhart X (x bar) chart (at top) with its accompanying range chart (at bottom). In this example, the X chart is estimating process location using the average of a five-piece subgroup at each time period; the range chart estimates process variation using the difference between the maximum and minimum measurements in the five piece sample. The choice of subgroup size is based on a number of considerations, including economics, desired sensitivity in detecting process shifts and the dynamics of the

TECH TIPS  Most process performance estimates (and some process capability estimates) are essentially useless to your customers.

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process itself, which dictates a rational subgroup. A proper control chart plots the data in time sequence—the data on the far left-hand side of the chart is from the earliest time period, and each subsequent value to the right corresponds to a later time period. In this way, a control chart is perfectly suited for processes, which, by their very nature, occur over time. Each subgroup represents a process sample at a given point in time, and provides an estimate of the “short-term” process location and variation. The control limits are calculated using the average of all the short-term (for example, subgroup) estimates. Process control is thus synonymous with process stability—stability is evident when the short-term estimates provide a reliable prediction of longerterm behavior. This explains why it is critical for the data to be plotted in the order they occurred in the process; otherwise, the short-term estimates are flawed. The control chart is further enhanced using run test rules to look for trends within the control limits, providing additional evidence of process instability. Error: Neglecting the order of the data, or plotting random samples from a batch where the sequence of production is unknown. Proper approach: Plot the data on the control chart in the order it occurred in the process. This is easier to do if the data is recorded and analyzed in real-time by the process personnel. The process sigma value in the capability equations is based on the average range R (r bar), so that process capability relies on accurate estimates of both x and R . If the range chart is out of control, then a single estimate for R is not meaningful—the process variation is not stable; it is changing and cannot be estimated by a single value. In this case, meaningful control limits cannot be established for the X chart. If the range chart is in control, then R is a reliable estimate of the process variation, and is used for calculating the X control limits. If the X chart is out of control, then the process location is unstable and similarly cannot be estimated by a single average value.

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Figure 1: X-Bar / Range Chart of Subgroups 1-40

This is a sample X /Range control chart. Source: From SPC Demystified (McGraw Hill, 2011), used with permission

Figure 2: Process Output on Histogram

Here is a histogram of data sampled from a process. Source: From SPC Demystified (McGraw Hill, 2011), used with permission

Figure 3: Example of Process NOT in Statistical Control

This is a control chart of data used in Figure 2. Source: From SPC Demystified (McGraw Hill, 2011), used with permission

April 2011 | QUALITY

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When both charts are in control, the natural variation inherent to the process may be estimated. This is the level of variation expected from the process over time. This estimate of common cause variation is improved with additional data. Notice how any single subgroup, or interval of 5 or 6 subgroups, do not provide a full picture of the common cause variation in Figure 1. Sufficient data—at least 25-30 subgroups of size five; more subgroups for smaller subgroups—are needed over a sufficient time period to experience the common causes inherent to the process. Error: Reporting capability index for a short time interval, such as a single shipment. Proper approach: Update the capability index only when the process undergoes a sustained shift. A process in control has, by definition, a single capability index.

A process that is stable may be approximated by a single distribution. A process that is out of control has multiple distributions. A special cause, referred to as a process shift when it is sustained, is evidence of a new process distribution. The special cause has the effect of changing one or more parameters of the in-control distribution: its location (estimated by average or median), spread (estimated by standard deviation) and shape (including skewness and kurtosis). While some statisticians suggest the

It should be obvious that a process and its statistics are only predictable if the process is stable; an unstable process— such as one influenced by special causes—is chaotic and unpredictable. If the process is out of control, the average, average range, and resulting process sigma and capability statistics include the effects of special causes, which add a statistical bias to their estimate. It is uncanny how often practitioners choose to present their capability indices with histograms instead of control charts. Note the histogram shown in Figure 2, obviously from a well-controlled process. Or is it? The data used to generate Figure 2’s histogram is shown on the control chart of Figure 3. The time sequence of the data is ignored in the histogram, thus preventing proper analysis of stability. For a set of sample data, the histogram is both misleading and meaningless, without an accompanying control chart. Error: Reporting capability index when the process is not in control, or its stability is unknown. Proper approach: Always report the process capability index with the accompanying control chart that verifies the state of process control. A capability index should be considered unreliable without the control chart used to estimate its parameters.

normal distribution is prevalent, realworld processes are designed to meet specific needs and may be sufficiently non-normal by design—mechanical stops are introduced to truncate the output; process improvement efforts move the process center closer to an optimal value; measurement scales (such as pH) may be inherently nonnormal; measurements may be bounded by a physical limitation (flatness must be a positive value). Once statistical control is established, a meaningful statistical distribution may be fit using SPC software. The Kolmogorov-Smirnov (K-S) goodness of fit test is typically used to pick the best fit distribution from the possible distributions. If the distribution is sufficiently non-normal, the standard process capability calculations, which are only applicable to a normal distribution, must be adjusted. For example, the 0.00135 and 99.865 percentiles of the fitted distribution may be used to determine the comparable non-normal Cp. Error: Applying the standard process capability calculations to process data that is not well-approximated by a normal distribution. Proper approach: Once statistical control is established, use the K-S statistic to determine the best distributional fit. Adjust the standard equations to

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provide equivalent levels of protection for non-normal distributions. When a process is out of control, or its stability is unknown, a typical recommendation is the use of the process performance indices. This method suffers from a fundamental flaw—a single estimate of a parameter is unreliable for an unstable process. When the process is out of control, the sample standard deviation will include the effects of one or more distributions, the impact of which is dependent on the

Most process performance estimates (and some process capability estimates) are essentially useless to your customers. relative number of samples from each distribution, as well as the quantitative differences between the distributions. Each distribution may or may not be well approximated by a normal distribution, making the standard calculations irrelevant. Deming discussed his All or Nothing Rule for determining the economic sample size based on the cost of undetected errors. For unstable processes, he invoked the Orsini modification, which essentially led to 100% inspection for critical characteristics. Error: Assuming a random sample will adequately quantify an unpredictable process. Proper approach: 100% inspection of all units in the shipment, or proper process capability analysis as described above. Q Paul Keller is president & COO of Quality America (Tucson, AZ). For more information, call (800) 722-6154, e-mail [email protected] or visit www.qualitymaerica.com.

QUALITY ONLINE For more information on statistical process control, visit www.qualitymag.com for the following: • “New Approaches to SPC” • Podcast: “An Overview of SPC and Justifying a Software Expense” • “Six Steps to Shop Floor Acceptance of SPC Software”

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FREEar in w! Web o ter N s

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How can Optical Measurement Improve Industrial QC? May 12, 2011 | 2pm EDT In the last 30 years, development of portable measurement has been a major evolution in the field of metrology, as it has brought the control process closest to the part, directly on the production line. More recently, the use of optics as a dimensional measurement tool has disrupted conventional control methods. Optical solutions can easily overcome the mechanical limitations of most existing portable measuring solutions by making it possible to automatically and seamlessly position the measuring tool with respect to the part. Using optical technologies, and especially dynamic referencing, can help drastically reduce major causes of measurement uncertainty.

Benefits for Attendees: • Discover optical CMM technology. • Learn how to combine optical probing and 3D scanning efficiently. • Understand how optical reflectors can increase the accuracy of measurement and simplify the measurement process. • See real case studies from the aeronautical, automotive and marine industries.

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uch has been made within the quality assurance community of the tremendous advantages—and limitations—of Six Sigma and lean management techniques in business. Companies across the globe have lauded the methodologies for their efficiency and cost-cutting potential, while others decry them for leaving little room for long-term, innovative thinking and the nuances of employee and customer relationships. Fortunately, certain individuals have pioneered ways to solve this dichotomy. One such leader is Forrest W. Breyfogle III, creator of the Integrated Enterprise Excellence (IEE) methodology—a system that blends the analysis of Six Sigma thinking with a foresight for innovation. Breyfogle is the author of 13 books and more than 90 articles on the topic of quality improvement. He is the presi-

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Forrestt B Breyfogle reyfogle III is the CEO of best practices consulting company Smarter Solutions Inc., author of multiple books that empower businesses to lead effectively and the innovator of the Integrated Enterprise Excellence System— a process that lies at the heart of these achievements. BY GE NE VI E V E D I E SI N G , ASSO C I ATE E D I TO R

dent, founder and CEO of best practices consulting firm Smarter Solutions Inc. (Austin, TX) and the recipient of the 2005 American Society for Quality Crosby Medal for Implementing Six Sigma, 2nd edition. The award is presented to a person who has authored a distinguished book contributing significantly to the extension of the philosophy and application of the principles, methods or techniques of quality management. Yet perhaps most importantly, Breyfogle has shared his knowledge

with countless companies and empowered them to transcend the limitations of their current management techniques, resulting in long-term, company-wide improvements. The secret, Breyfogle says, is learning how to ask the right questions within your business. Instead of singularly focusing on process management, businesses must take long-range views of their operations and decide how to implement improvements in continuous, flexible ways.

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 If Breyfogle can share one general set of guidelines he’s gleaned from his experiences, it would be that one cannot underestimate the importance of asking the right questions. Source: Smarter Solutions Inc.

“Too often we ask about the specifics we understand, rather than asking about the enterprise view of success,” Breyfogle explains. “Businesses end up putting very tight controls on the processes they understand and assume all will work out. They are asking the wrong questions.”

FROM ENGINEER TO AUTHOR Breyfogle was born in St. Louis in 1946, and entered the University of MissouriRolla’s mechanical engineering program in 1964. Upon graduating with a Bachelor of Science in 1968, he received a job offer for an engineering position at IBM. “Times were different when I graduated from college,” Breyfogle acknowledges. “IBM actually called me for an interview. Previous to the IBM call, I had been interviewing at chemical companies, but after a trip to IBM, I became convinced to become an IBM-er. Isn’t it amazing how something simple as a phone call can redirect one’s life?” Indeed it is. That phone call resulted in Breyfogle spending 24 years with IBM. Breyfogle began his career in the development side of the company as an engineer—returned to school and earned a Master of Science in mechanical engineering from the University of Texas at Austin in 1975—and later transferred to the product test segment of the company. From 1980 to 1992, he helped IBM apply Six Sigma methodology to testing, development, manufacturing and service organizations. “While working in product development at IBM, I took a Design of Experiments (DOE) course that redirected my career,” Breyfogle explains. “I started applying DOE techniques in product development and later product test[ing]. In 1980, I requested that IBM create a job for me as an internal statistical consultant. They bought into this, and for the last 12 years with the company I found my own work—helping people solve problems using quality principles.” At this point, Breyfogle was ready for a new chapter in his career. He had sharpened his analysis skills with the aid of a

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Breyfogle spent 24 years as an engineer at IBM before becoming an internal statistical consultant. Source: Smarter Solutions Inc.

“Too often we ask about the specifics we understand, rather than asking about the enterprise view of success,” Breyfogle says. Source: Smarter Solutions Inc.

Breyfogle is the author of 13 books and more than 90 articles on the topic of quality improvement. Source: Smarter Solutions Inc.

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statistician mentor, and sought to share his knowledge with the quality industry. “During this time, I thought that there was a need for a book that provided practitioners a how-to roadmap,” Breyfogle says. In 1992, his first book, Statistical Methods for Testing Development and Manufacturing, was published. Breyfogle’s research coincided with his retirement, which, incidentally, also was the approximate time IBM began to implement Six Sigma practices in its operations. Breyfogle could see that IBM needed a better approach in its implementation. “I was convinced that the way that [IBM was] approaching the task would not lead to success,” he notes. “Because of this, I included a roadmap for implementing the tools of Six Sigma in the appendix of my book.” Breyfogle was correct in his assumption that IBM needed a better method, he says—the company “did not have success” in its Six Sigma deployment. There was no one better poised than Breyfogle to take this lesson to heart, and he did just that as he embarked on engineering the IEE structure.

THE IEE SYSTEM EVOLVES Breyfogle formed his IEE method based on a recurring problem he initially saw at IBM, and subsequently, throughout companies across the globe. The system teaches managers how to establish goals, prioritize work efforts and continuously develop organizational progress. The system helps companies improve their bottom lines by blending analytics with new ideas. Breyfogle says that if more companies focused on the cause of problems within their organizations instead of their symptoms, they would have a better idea of how to improve. “I felt that organizations were answering the wrong question, or at least not the best question, to the third decimal place,” he says. “I use this term—to the third decimal place—to represent a behavior where organizations attempt to make decisions with seemingly very exact conclusions that ignore the assumptions that were used in the effort,” Breyfogle explains. “It is like estimating the cost of the organization’s cost of poor quality to the dollar, using the direct cost of the scrap materials. “When you see a number with six

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Forrest Breyfogle III is Quality’s 2011 Professional of the Year. Source: Matthew Emmons

ent that the organization [needed] more business. I then asked about the improvement projects that they were being conducted in marketing and sales. I got a blank stare from the company’s tour guide. “The business was focusing on improving their manufacturing operations as a silo activity,” Breyfogle continues. “However, enterprise gains could have been much larger if significant process improvement efforts were made to their marketing and sales efforts; [or were] determined from a big-picture assessment.” Thus, the IEE business management system was formed to integrate predictive scorecards, analytically thoughtout strategies and improvement efforts so that the business as a whole benefits.

GOING SOLO or seven digits, it is assumed to be very accurate, but is it?” he continues. “If the cost of poor quality did not include the rework labor, the management time chasing problems, lost business impact, extra shipping costs.... they may have answered the wrong question.” In other words, the IEE system teaches companies to take a few steps back before they start asking questions. Which begs the inquiry: What types of questions should companies ask? “Why are we not profitable?” Breyfogle suggests. “Why are our margins lower than our competitors? These are the questions that lead to the cost of poor quality.” As Breyfogle continued to help businesses focus on these types of questions, he noticed many of the companies made similar mistakes in their process improvement attempts. Breyfogle saw that Six Sigma, and later lean Six Sigma deployments, often would lead to what he calls “opinion-based silo projects” that would not, ultimately, benefit a business as a whole. “At one company’s lean Six Sigma event, where I spoke, the site’s general manager described how they were gaining much from lean,” Breyfogle explains. “During my tour of his manufacturing facility, I commented to the lean practitioner guide that it seemed to me that they were doing a good job applying lean; however, since there was so much idle equipment, it was appar-

After his departure from IBM in 1992, Breyfogle began consulting full-time, which led him to form the management consulting firm Smarter Solutions. In 1997, Breyfogle was called upon to give Six Sigma black belt training at Colchester, VT-based aircraft manufacturer Bombardier’s facilities in Ireland and Toronto, Canada. There, he became familiar with the Six Sigma process improvement tool DMAIC, which stands for define, measure, analyze, improve and control. “At this time, I was under contract for the creation of a second edition to my Statistical Methods book,” Breyfogle says. “Upon completion of my delivery of the black belt training, I thought that there was a need for a Six Sigma book that could guide practitioner through the DMAIC roadmap. I convinced my publisher that instead of creating a second edition, a new book should be created. Hence, Implementing Six Sigma was published in 1999. Breyfogle’s list of published books has grown at pace with his expertise. In the first quarter of 2008, he authored a four-volume set of books: The Integrated Enterprise Excellence (IEE) suite, which documents the IEE system for enterprise management in the 21st century. As Breyfogle—an ASQ certified quality and reliability engineer and ASQ Fellow—developed his know-how, he continued to conduct lean Six Sigma workshop coaching sessions,

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BALL BAR - DUMBELL as well as executive training sessions throughout the world. Breyfogle went on to publish more than 90 technical articles for separate publications, and appeared on television and radio to speak about enterprise improvement methodologies. He also became a member of the board of advisors for the University of Texas’ Center for Performing Excellence. Breyfogle’s peers have no shortage of accolades for his work. Perhaps James Bossert, Bank of America’s senior vice president, sales performance and analytics, says it best, calling Breyfogle’s books “some of the most profound thinking in the areas of Six Sigma and integrated management.”

UNIVERSAL APPLICATION If Breyfogle can share one general set of guidelines he’s gleaned from his experiences, it would be that one cannot underestimate the importance of asking the right questions—or identifying what those questions are. “If you are to be answering what you think is the wrong, or the not-best question for the business as a whole, see what you can do to work with management to help them gain collective insight to what can be done differently to better orchestrate the best activities within the company,” Breyfogle advises. Breyfogle feels that this lesson can be shared universally, and is particularly relevant in light of recent high-profile business and government failures. “With the many crises that we have recently experienced, such as our banking system problems, the BP oil spill, Dell’s accounting issues that led to fines and Toyota’s quality issues, it seems to me that it is obvious that our current management system is not working,” he says. Breyfogle says the issue, as usual, lies in managers addressing symptoms of the problem instead of its root cause—and getting muddled in the process. “What often is used within existing business practices is stoplightgoal-based scorecards that lead to firefighting and playing games with the numbers, which can result in very destructive behaviors,” Breyfogle notes. “Often, the current management system also leads from strategies using techniques such as the balanced scorecard and Hoshin planning. It seems

to me that what I have described are very large business management issues, where virtually no effort is being expended to truly examine and address these unhealthy practices.” Breyfogle says that organizations could have done a better job of handling—and preventing—such catastrophes by seeing them coming in the first place, and the IEE system could have helped them achieve that. “What organizations needed, in my opinion, is a business system reinvention that leads organizations toward achievement of the three ‘Rs’ of business; for example, everyone doing the right things, and doing them right, at the right time,” Breyfogle explains. “The Integrated Enterprise Excellence system helps organizations achieve this through a no-nonsense roadmap that integrates predictive scorecards with analytically/innovatively determined strategies, and improvement efforts that benefits the big picture.” In other words, businesses could do a better job of staying on track by sticking to thought-out strategies and learning how to predict—and handle—potential outcomes. Breyfogle says that an integrated business system allows a company to learn the cause and effects within its operations so that even in a tentative business environment, a company is prepared to take action. “With the IEE system, the analyze phase should have flagged the unsatisfactorily high risks that were being taken through the creation of policies that loaned money to people who could not reliably afford the loan’s repayment,” Breyfogle explains. “With the IEE system, Toyota should not have lost sight of product quality in order to meet their 2003 strategy of becoming the largest automobile company in the world by 2010.” Issues such as these are precisely what keep Breyfogle motivated to keep teaching. “I am concerned about the way things are going within the United States and other parts of the world,” he says. “I am concerned about the lifestyle my grandchildren will have unless we start doing something different now relative to how policies are created and how both businesses and governments are run. The Integrated Enterprise Excellence system is my attempt to help organizations address these real issues.” Q

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CA SE ST U DI ES

 Caterpillar called on Hexagon Metrology’s special systems group to partner on designing and building a new cooling chamber outside of its metrology laboratory; scheduling and executing the implementation of the new system; and setting the workflow contingency plan into action. Source: Hexagon Metrology

New CMMs Lend Throughput Advantages Hexagon Metrology’s temperature sensor-equipped CMM enabled Caterpillar Americas to gain real-time compensation in its cooling chamber.

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any a quality control manager agonizes over improving his inspection processes, maintaining productivity in his departments and keeping his metrology equipment running in peak condition. That same manager also knows that once you throw the ‘on’ switch to replace a coordinate measuring machine (CMM), a strategic contingency plan must steer the department in the interim period. Paulo H. Pereira, chief metrologist at Caterpillar Americas operations division (East Peoria, IL), was facing what every manufacturing enterprise must eventually contend with—turning over

old equipment and upgrading to new technology. In particular, one of Pereira’s large gantry CMMs was nearing the end of its lifecycle. As the precision instrument entered its twilight years, the effort to keep it running became increasingly difficult. Machine downtime escalated, and major maintenance investments were required to keep it going.

MOVING OUT THE OLD, BRINGING IN THE NEW A new DEA Lambda SP coordinate measuring machine from Hexagon Metrology (North Kingstown, RI) was chosen as the replacement system.

When compared to the old CMM, there were significant structural differences. The welded frame and the moving bridge were extremely heavy on the older model. The machine spanned more than 4 meters on one side and had a built-in walkway over the bridge. The new system’s moving parts are light and agile aluminum extrusions. This streamlined design allows the CMM to accelerate at faster rates and drive at higher speeds, giving it a throughput advantage. For a green bonus, the lighter weight CMM also operates using less power. The new system would be used to inspect mostly large prismatic parts weighing thousands of pounds. The sturdy CMM is designed for applications requiring an extra-large measuring volume for dimensional inspection of oversized precision components such as turbines, marine engines and satellite parts. The gantry CMM architecture allows for easy part loading and integration with part transportation systems. Not your father’s CMM, the DEA includes technical advances such as a dual drive encoder system on the main carriage, slant bridge technology and adaptive compensation of thermallyinduced variations (ACTIV) structural thermal compensation. The dual drive encoder system is installed on both sides of the large sliding carriage of the CMM and greatly reduces the tendency for the yaw motion of the axis. The dual drives essentially smooth out the motion of the carriage. The dual scales and encoders maintain side-to-side positioning accuracy of

BENEFITS  The DEA Lambda demonstrates a 60% increase in maximum velocity and a 37% increase in acceleration from previous models.  Compared to the older machine, the new CMM is far less sensitive to temperature fluctuations.

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 The new CMM’s wider bearing spread and lower overall profile contributes to greater rigidity and a lower center of gravity, which in turn contributes to lower deflection of the structure at higher rates of acceleration and velocity.

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The CMM inspection process captures data on diameters, flatness, true positions, with hundreds of features on a single part. Source: Hexagon Metrology

the carriage—up to four meters on standard machines and greater in nonstandard applications—particularly the wider X-axis capabilities of the Lambda. This system also allows geometric compensation on both sides of the carriage, rather than just a single side, which contributes to better accuracy.

DOUBLY BENEFICIAL The benefits of slant bridge technology are twofold. By tilting the surface of the air bearing guideways, the bearing spread can be made wider than a conventional vertical rectangular structure, while maintaining a lower overall profile. The wider bearing spread contributes to greater rigidity. The lower profile contributes to a lower center of gravity, which in turn contributes to lower deflection of the structure at higher rates of acceleration and velocity. ACTIV structural temperature compensation uses a network of temperature sensors placed in strategic locations throughout the CMM structure. These sensors monitor temperature at those positions, and software developed from extensive thermal modeling of the CMM structure provide real-time compensation. Compared to the older machine, the new CMM is far less sensitive to temperature fluctuations.

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MAKING THE RIGHT CALL Choosing a replacement CMM was just the start of this particular project, which was more intricate than most system upgrades. Caterpillar called on Hexagon Metrology’s special systems group to partner on the project. The endeavor would entail designing and building a new cooling chamber outside of the metrology laboratory; scheduling and executing the implementation of the new system; and setting the workflow contingency plan into action. Caterpillar also would arrange for the removal of the older, heavier CMM. Like any major capital investment, getting approval for the purchase took several months. It also took a considerable amount of time to clearly define what the system should look like and to construct a contingency plan for inspecting parts when the old CMM goes offline and is removed. The third piece of the puzzle was the construction of a cooling chamber near the metrology laboratory, where components queue up to be measured. Under the new plan, these large parts are placed on carts using overhead cranes and sent to the cooling chambers where their temperature is stabilized prior to inspection. According to international metrology standards, all measurements should be made at 20 C.

According to Pereira, a two-year implementation is certainly not out of bounds when executing a complex project, where steps are taken incrementally with the least impact to the production cycle and productivity. A good amount of planning takes place on both sides to determine the need and to make it happen seamlessly. Inspections had to continue even when one of the four CMMs in the department was shutdown. A thoughtful contingency plan was required to maintain operations. Moving from an older CMM to a new, state-the-art CMM provides a wide range of advances introduced in the past decade. The DEA Lambda is precision-built for high speed, high accuracy inspection of huge components, that require open, modular, easily customizable structures with virtually unlimited measuring volumes. There is a 60% increase in maximum velocity and a 37% increase in acceleration by moving to the new CMM. This pure increase in dynamics, combined with increased probing speed and new scanning technology, enable the customer to experience a 40 to 50% increase in throughput on their part programs. Hexagon Metrology Inc. (847) 931-0100 www.HexagonMetrology.us

April 2011 | QUALITY

49

QUALITY

PRODUCTS ROTARY SERIES ENCODERS Heidenhain low profile incremental rotary 1000 and 1100 series encoders have block commutation tracks designed for use in small-dimensioned servo motors. They have a 35-millimeter housing diameter. They have opto-ASIC based photoelectric scanning with integrated interpolation. They can be connected to almost all standard subsequent electronics for control of digitally controlled servo motors up to edge lengths of 40 millimeters and 55 millimeters, and are designed for various applications in the automation industry. HEIDENHAIN CORP. (847) 490-1191 WWW.HEIDENHAIN.COM

SURFACE METROLOGY SYSTEM The NPFLEX-LA Surface Metrology System quantifies true lead angle and surface roughness for the control and reduction of fluid leakage of rotary dynamic sealing systems. It defines critical surface parameters of machined shafts, which directly impacts seal integrity and prevents premature failures in the field to solve a critical precision machining industry problem. It is gage-capable and measures lead and surface texture, independent of part alignment. BRUKER CORP. (520) 741-1044 WWW.BRUKER-AXS.COM

OPTICAL COMPARATOR TOUCH-TRIGGER PROBE HEAD The PH20 probe head has high-speed point capture with minimal coordinate measuring machine (CMM) movement. It increases touch-trigger CMM inspection throughput up to three times and can be used on smaller CMMs. The PH20 is available for new CMMs, as well as retrofit machines using shank or quill mounting. It can use most existing inspection programs for indexing heads without modification and requires no compressed air. RENISHAW INC. (847) 286-9953 WWW.RENISHAW.COM/PROBES

50

QUALITY | April 2011

The 14HE optical comparator has a machined chart ring with a recessed screen to protect internal optics and align the screen to the optical axis. The highresolution angled glass screen measures 14 inches. It has a large-format vernier protractor with one minute graduation, coated telecentric par focal optics and a quick-change single lens mount. It can be used with overlays or a variety of readout formats. It has published optical and travel accuracy specifications and NISTtraceable certifications. DORSEY METROLOGY (845) 454-3111 WWW.DORSEYMETROLOGY.COM

www.qualitymag.com

VERTICAL CNC HONING SYSTEM CYLINDRICITY MACHINE The MMQ 200 Formtester provides the measurement of surface finish parameters according to accepted ISO, ASME and JIS standards. With the combined hardware/ software MMQ 200 surface finish option, it has reduced set-up and measurement cycle time, and needs one piece of equipment for both form and surface measurements. It was designed with roughness measurements and can sample data with spacing down to 0.5 micron. MAHR FEDERAL INC. (401) 784-3275 WWW.MAHR.COM

The SV-1005 series vertical CNC honing system has an integrated air gaging system that has closed-loop control of tool size, along with downloadable SPC data. It automatically controls hole size to accuracies of 0.25 μm without operator intervention, working in a bore size range of 3 to 65 millimeters in diameter. It was designed for automated, highprocess capability production of small engines, hydraulic valves, fuel injectors, gears, compressor parts, turbocharger housings and gun barrels, in medium and high volumes. SUNNEN PRODUCTS CO. (314) 781-2100 WWW.SUNNEN.COM

MODULAR ENCLOSURE The Hemco coordinate measuring machine (CMM) rooms are designed to maintain a ±1 degree temperature consistently. The modular room provides the environmental precision and accuracy necessary for companies that need to meet tight specification standards. These modular enclosures are built to exact specifications. Wall and ceiling panels are chemical resistant and non-porous. HEMCO CORP. (800) 779-4362 WWW.HEMCOCORP.COM

ID/OD Gages Customizable to Meet Your Application Needs Fast-precision ID/OD shop floor gaging Readout options include dial/digital indicators and transducers for highest sensitivity Easy to adjust for various sizes - friction free trannsfer ensures high performance Applications up to 98 inches/2500 mm Available for fast delivery

-

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Mahr Federal - The Application Experts Contact Mahr Federal Inc., Providence, RI Phone: 800-343-2050, Fax: 401-784-3246 or E-mail: [email protected], Internet: www.mahr.com

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April 2011 | QUALITY

51

May 17-19, 2011 Eastern States Exposition West Springfield, Massachusetts

For What’s Around the Curve. By anyone’s measure, manufacturing’s been thrown some serious curves recently. A visit to EASTEC 2011 can keep you ahead of them. EASTEC is three days of straightforward insight into vital manufacturing technologies, progressive management strategies, the latest lean thinking, and clear advice on making your operations greener. Successful manufacturing means negotiating the tightest curves. EASTEC can help you see around them. Make your attendance plans today! www.easteconline.com • 800.733.4763.

|

QUA LIT Y PRO D U CT S

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IN-SITU PROBE The Hygropin in-situ probe requires an 8 millimeter diameter hole at the test site. It can reach stable values within five minutes. It has two independent probe inputs to gather simultaneous readings from both an in-situ probe and ambient probe on two independent channels which can be fitted in any combination. It has data recording for 10,000 measurements and an onboard trend indicator. PROCEQ (724) 512-0330 WWW.PROCEQ.COM

RESEC SYSTEMS, INC.

AUTOMATED INSPECTION SOFTWARE The iNspect Express Version 1700 was designed for automated inspection and quality assurance for BOA smart cameras. The software interface allows operator set up and deploy solutions with no programming. The new version of BOA software introduces optimized algorithms, optical character recognition (OCR) and 2-D matrix readings, as well as improved calibration tools. It includes a PC-based application for displaying images and results from multiple BOA cameras on the same screen. Operators using this application can monitor production, change job files and review inspection history of any BOA connected to the local network. TELEDYNE DALSA (978) 670-2000 WWW.DALSA.COM

Precision Sorting Equipment

FLOW MODELING SOFTWARE Version 5.1 of Fluent for CATIA V5 is a flow modeling technology within the V5 product lifecycle management (PLM) environment. This version has meshing, workflow and post-processing enhancements and aligns with the Ansys vision of simulation driven product development (SDPD). These enhancements allow more options in creating meshes than previous versions, allow faster solutions with smaller files and rapid post-processing of large cases. ANSYS (866) 267-9724 WWW.ANSYS.COM

Fast, Accurate Inspection of Small Parts • • • • • •

100% Inspection Up to 10,000 Parts/Hour Optical Measurements to ±0.0001” Flexibility for Different Parts Easy to Operate Low Cost Benchtop Units

93-A South Railroad Avenue - Bergenfield, NJ - 07621 Phone: (800) 394-6758 www.resecsystems.com

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April 2011 | QUALITY

53

SUCCESS THROUGH QUALITY

2011 4HE)NTERNATIONAL4RADE &AIRFOR1UALITY!SSURANCE

sMeasuring Technology sMaterial Testing sAnalysis Apparatus sOptoelectronics sQuality Assurance Systems sOrganization sIndustrial Image Processing

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www.schall-virtuell.de www.control-messe.de

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QUA LIT Y PRO D U CT S

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DATA MONITORING SYSTEM

HIGH PASS FILTERS The CHPFL series of high pass filters was designed for test equipment and general lab use. It comprises five models, with frequency up to 1 gigahertz. It has out-of-band rejection and 50 ohm subminiature version (SMA) connectors. All filters in the CHPFL family are rated at +4 watts, with an operating temperature of -40 C to 85 C and storage temperature of -55 C to 100 C. MACROVISION INC. (215) 348-1010 WWW.MACROVIS.COM

The LogMessage system has been designed to record data for applications such as remote monitoring, product testing, quality and reliability testing, process monitoring, research and development (R&D), and fault analysis. This system is available in seven different configurations that incorporate up to 30 analog inputs with a sampling rate up to 1,200 hertz. It can measure voltage, current, thermocouple or resistance temperature detectors (RTD) sensors. CAS DATALOGGERS (800) 956-4437 WWW.DATALOGGERINC.COM

Measurably Different Fetura® sets the new benchmark for optical metrology throughput Fetura Vision Metrology Systems combine the world’s fastest optical zoom technology with powerful software and precision mechanics to offer a measurable advantage in offline inspection and quality control.

• NEW Multi-Sensor Option! • Fastest Optical Zoom • Color Edge Detection • Intelligent lighting • Optional Laser Scanning • Visual Basic Scripting • Multipoint Autofocus Visit us at:

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Dial and Digital Indicators Customizable to Meet Your Application Needs Maxum III the most rugged Digital Indicator for on the job performance Digital Indicators are available in long range or comparative versions for highest resolution All AGD Indicators are American made and fully repairable - providing a lifetime of service Avialable for fast delivery

US/Can: 800-429-0257 [email protected]

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Mahr Federal - The Application Experts Contact Mahr Federal Inc., Providence, RI Phone: 800-343-2050, Fax: 401-784-3246 or E-mail: [email protected], Internet: www.mahr.com

www.qualitymag.com

April 2011 | QUALITY

55

CL A SSIF I ED

To place a classified ad in Quality, call Sunny Coverly at (610) 932-8350, or FAX: (248) 283-6587

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Quality Magazine Classified Ads Policy Classified ads are accepted at the discretion of the publisher, and are limited to:  Used/Refurbished Equipment  Aftermarket Accessories and Replacement Parts  Services, including laboratories  Employment  Black & White or 2-color ads (no 4-color ads accepted) New equipment in a classified ad will be rejected unless the company has a contracted and approved display advertising program.

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Carl Zeiss Industrial Metrology [email protected] (248) 867-3699 www.zeiss.com/ct-services

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April 2011 | QUALITY

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VisionGauge® Digital Optical Comparator (Patent Pending) VisionGauge® Digital Optical Comparator, The Fastest, Easiest, Most Accurate Way to Compare a part to a CAD FileTM More accurate, smaller footprint provides more than twice the through put of traditional comparators and can collect a complete device history. Fully portable, can be moved across the shop floor without requiring re-calibration.

VISIONx Inc. 514-694-9290 [email protected] www.visionxinc.com

58

PixeLINK has released the PL-E530 series of machine vision cameras. • Available in 1.3, 3.0, or 5.0 MP • Aptina CMOS Sensor • Color or Monochrome Versions • 8 & 10-bit output • Rolling shutter • Simple and easy to use SDK for all cameras

QUALITY | April 2011

The MetraSCAN Optical CMM 3D Scanner by Creaform The arm-free handheld MetraSCAN™ 3D scanning system and the C-Track™ dualcamera sensor form a unique duo that generates the most accurate measurements in lab and on the shop floor. Combined with the HandyPROBE arm-free and portable CMM, this powerful inspection solution increases the reliability, speed and versatility of the measurement process.

Creaform 1.302.444.6696 www.creaform3d.com

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Calibration Services Hexagon Metrology’s Universal Calibration Services is your one-stop shop for on-site calibrations, no matter what you need to calibrate. Competitive rates, nationwide ISO 17025 certified for: • All brands of CMM • Machining Centers • Boring Mills • Turning Centers • Rotary Tables • Surface Plates

www.zeissmetrology.com Carl Zeiss Industrial Metrology 6250 Sycamore Lane North Maple Grove, MN 55369 (800) 327-9735 Hexagon Universal Calibration Services www.HexMet.us/qshucs 248-449-9508

Custom Gage Applications • Fast and Accurate • Simplified Dimensional Control for in-process or post-process inspection of lengths, depths, diameters, position of slots or shoulders and angle of taper (male or female) • Mechanical or Electronic Indicators • Bench top or Hand Held • Quick Change and Interchangeable • Standard Gages or Customer Designs

Dow Gages for Quality Control Since 1946 169 White Oak Drive, Berlin, CT 06037 Phone (860) 828-2450 • Fax (860) 828-2451 • [email protected]

S iemers I nspection S ervice, Inc. Est. 1983 Dimensional Inspection Statistical Process Control First Piece/Multiple Lots

ISO/IEC 17025-2005 713 W. Prairie St. Tel: (269) 649-4434 Vicksburg, Michigan 49097 Fax: (269) 649-2338 Call for a brochure or visit our Website: www.siemersinspection.com

Dimensional Measuring System ProTable™ is a battery operated dimensional measuring system designed for use in a manufacturing environment. Measurements are displayed with a resolution of .001in., 01mm, or .001cm. Steel bearings, temperature and non-linear error compensation maintain an accuracy of ±.010 in. (±.003 optional) over the entire range. Standard models are available to measure up to 19.5 feet. Custom designs also available.

www.proscale.com [email protected] 828-654-7920

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April 2011 | QUALITY

59

A DV E RTI SI NG I NDEX ADVERTISER

PAGE

Assetsmart

3

www.assetsmart.com

Bal-tec

47

www.precisionballs.com

Carl Zeiss Industrial Metrology

34

www.zeiss.com/metrology

Creaform

27

www.creaform3d.com

11, BC

www.cybermetrics.com

Dorsey Metrology International

25

www.dorseymetrology.com

Easy-Metric

27

www.easymetric.com

REGIONAL MARKETING

Hexagon Metrology Inc.

15

www.hexmet.us

New England and Mid-Atlantic Barbara Grim 1288 Centerton Rd. Pittsgrove, NJ 08318 Phone: (856) 358-4800 FAX: (856) 358-0900 [email protected]

Hommel-Etamic

5

www.hommel-etamic.com

27

www.imada.com

1, 51, 55

www.mahr.com

7

www.mark-10.com

Micro-Vu

35

www.microvu.com

MicroRidge Systems Inc.

53

www.microridge.com

Mitutoyo America Corp.

IFC

www.mitutoyo.com

Origin Technologies Corp.

30

www.origintech.com

P.E. Schall GmbH & Co. Kg

54

www.control-messe.de

PixeLink

25

www.pixelink.com

Qioptiq Linos Inc.

55

www.qioptiq.com

Renishaw

17

www.renishaw.com

Resec Systems Inc.

53

www.resecsystems.com

9

www.stindustries.com

Society of Manufacturing Engineers

52

www.easteconline.com

UBM Canon

56

www.mdmeast.com

VisionX Inc.

13

www.visionxinc.com

Western Gage Corp.

51

www.westerngage.com

155 N. Pfingsten Rd., Suite 205 Deerfield, IL 60015

Cybermetrics Corp.

Group Publisher Darrell Dal Pozzo (847) 405-4044 [email protected]

Central and Southeast Bill DeYoe 109 Willow Springs Trail Mt. Holly, NC 28120 Phone: (704) 822-6434 FAX: (704) 822-6834 [email protected] Midwest, Southwest, West and Northwest Buck Bicek 5820 Middaugh Ave. Downers Grove, IL 60516 Phone: (630) 971-0904 FAX: (248) 502-1086 [email protected]

INSIDE SALES Inside Sales Manager Sunny Coverly 116 Cooper Ln. Oxford, PA 19363 Phone: (610) 932-8350 FAX: (248) 283-6587 [email protected]

Imada Mahr Federal Inc. Mark 10 Corp.

S-T Industries Inc.

WEB SITE

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

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

60

QUALITY | April 2011

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APRIL 2011

DEPARTMENTS 4NDT

Editor’s Note Leveling the Field

6NDT

Industry News

8NDT

Key to Quality The Evolution of the NDT Inspector

Source: Olympus NDT

9NDT

Hardness Testing 101

CERTIFICATION

10NDT

NDT Personnel Certification 101

23NDT Tech Showcase

Companies looking to certify their employees should follow these steps to certification.

24NDT Case Study

The Latest in XRF Analysis Acoustic Pulse Technology Streamlines Inspection

ULTRASONICS

14NDT Cracking Down on Defects Advanced techniques can be used to visualize defects in welds.

26NDT Products 28NDT Advertising Index

IN THE NEXT ISSUE

RADIOGRAPHY

18NDT

Back to Basics

Computed Radiography: Keep it Short and Simple

Eddy Current

Implementing a computed radiography program will help overcome economic and environmental challenges.

Acoustic Inspection

Liquid Penetrant

ABOUT THE COVER An inspector performs a weld inspection per AWS code using an Epoch 600 portable ultrasonic flaw detector and 2.25 MHz angle beam transducer. Source: Olympus NDT

Source: Quality Testing Services 2 NDT ● APRIL 2011

NDT SPECIAL SECTION

www.ndtmag.com

Br Bringing ring gin ng th the he ppower owerr of off LLEDs ED Ds to to o NDT! NDT! Whether you’re looking for a lightweight, hand-held inspection lamp or a complete overhead system, we have an LED light source to meet your needs!

OPTIMAX™ 365 LED Inspection Flashlight Powerful, cordless and rechargeable, high-intensity UV-A flashlight!  Nominal steady-state UV-A intensity of 18,000 μW/cm2 at 15 inches (38 cm)

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TRITAN™ 365 Multi-LED, Broad-Beam Inspection Lamp Provides wider coverage area than conventional UV-A inspection lamps. Compact design allows access into areas inaccessible to larger lamps.  Features three ultra-high-intensity UV-A LEDs for inspection, plus a convenient white light LED to illuminate dark work areas

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

 30,000-hour LED service life  Built-in fan keeps LEDs cool to maintain optimum light output  Choice of 8 foot (2.4 m) or extra-long 20 foot (6.1 m) power cord with AC plug

 UV-absorbing spectacles included

Hands-Free LED Inspection Kit

Modular NDT LED Inspection System

Features a versatile, palm-sized light source. Ideal for fluorescent magnetic particle and penetrant testing, and a variety of other specialized applications!

Innovative, track light-style, overhead inspection system. Perfect for NDT inspection booths, pre-inspections and screening applications requiring maximum uniformity of coverage over large areas.

 Compact, lightweight lamp with two ultra-high-intensity UV-A LEDs for inspection, plus a three-LED white light assembly for general illumination

 Nominal steady-state UV-A intensity of 5,500 μW/cm² at 15 inches (38 cm)  30,000-hour LED service life  Adjustable strap allows lamp to be worn on a hard hat or directly on the head for hands-free operation!

 Unique lamp mount/sprayer permits lamp and spray can to be mounted together for single-handed fluorescent yoke inspection

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 Features four broad-beam lamp heads, each with three ultra-high-intensity UV-A LEDs for inspection, plus one white light LED for general illumination Nominal steady-state UV-A intensity of 9,000 μW/cm2 at 15 inches (38 cm) 30,000-hour LED service life Built-in fans keep LEDs cool to maintain optimum light output Fully customizable! Move, adjust and add lamp heads onto track section according to your specific inspection requirements (additional lamp heads sold separately).  Optional remote control with three-position rocker switch provides added convenience and versatility  UV-absorbing spectacles included

   

late filters, three spare batteries, battery charging cradle with AC and DC cord sets, UV-absorbing spectacles and soft carrying case

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Leveling the Field Whether we realize it or not, nondestructive testing (NDT) is a big part of our everyday lives. A lot of times–and I’m guilty too–we take this measure for granted. When I’m driving in my car on the way to work, I don’t necessarily think about how all the components have been checked for reliability. I just assume it’s built to last. This is a testament to the NDT industry overall and how its testing evaluations have kept us safe as the demand has grown significantly across industries, most notably automotive and electronics. Kari O’Rourke Managing Editor [email protected]

W

With that said, this th t area of expertise doesn’t happen overnight. overnight overnigh The need for quality training is critical in the th world of NDT where visual longer make the grade. After all, inspections no llon technicians are essentially in charge of these technicia keeping us safe as they make key decisions that could safety ramifications. ld potentially ll have h However, before those tests are performed, there are steps that need to be taken to ensure proficiency. When it comes to the terms “qualification” and “certification” there tends to be some confusion in the industry as to which means what since both terms sound like they are describing the same thing. The American Society of Nondestructive Testing (ASNT) clearly defines these terms in their recommended practice, SNT-TC1A, Certification and Qualification of NDT Personnel: 䡲 “Qualification is comprised of three things: the organized education, the required examinations proving an individual has proper training and sufficient work experience in a particular inspection method.” 䡲 “Certification is a written testimony by an employer affirming that an individual has met the requirements of training and experience regarding a particular inspection method as stated in the company’s written practice.”

Depending on the test method, the hours fluctuate. For instance, eddy current, ultrasonic and radiography testing all require 40 hours of training–and that’s only for Level I. The certification levels range from Level I Limited, Level I, Level II to Level III and are ranked by how skilled a technician is. To find out more about the process, turn to pg. 10 where author Justin Lehmann gives an 4 NDT ● APRIL 2011

NDT SPECIAL SECTION

overview of the steps required to properly establish a qualification and certification program in your company. While there are a variety of standards that NDT professionals adhere to, Lehmann discusses qualification and certification schemes used in the United States. Also, if you are looking for more information on where to receive an education in NDT, visit the NDT Resource Center’s Web site at www.ndt-ed.org for a list of established programs where certification can be earned. Or, if you don’t see a location nearby, training courses are now conveniently being offered online and are administered by an ASNT Certified Level III. This also is a great way for those of you Level IIIs who are certified and are looking to dust off your skills. Like I said in a previous column, you’re never too old to stop learning. Mastering your fundamentals will help you to stay on top of evolving test methods and increase your competence in the field. Some other tools that might useful on your path to certification are social media sites such as Twitter and LinkedIn. Just by searching “NDT training,” several tweets come up with training schedules and job opportunities. If you haven’t already, follow us on Twitter at http://twitter.com/QualityMagazine, join the discussion with other members of the Quality community at the Quality Magazine LinkedIn Group page or friend us on Facebook. Coming up on May 4, we’re co-hosting our first virtual tradeshow Tech ManufactureXPO. This is a free opportunity for manufacturing professionals to attend educational sessions all at the simplicity of logging onto a home or work computer. Visit www.techmanufacturexpo.com for more conference details and to register today. www.ndtmag.com

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 Some vision dimensional metrology systems have streaming vision technology, which replaces conventional digital cameras and associated lighting with stroboscopic illumination, enabling a progressive scanning camera to capture images while the workpiece is in motion. Source: Mitutoyo America Corp.

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implemented. For example, there are CNC vision measuring systems capable of measuring radii, holes and other features with a total tolerance bandwidth of 0.5 micrometer. Interestingly, the pixel count of a vision metrology system’s digital camera is not a limiting factor because almost all the charged-coupled device (CCD) pixels are applied against the magnified image being scrutinized. This is in contrast to machine vision systems, which typically image fields of interest measured in square inches.

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July 2008 www.qualitymag.com

Measure with Vision Vision dimensional metrology can offer unique productivity enhancing opportunities. BY AL L EN J. CIUS

V

ision dimensional metrology should not be confused with machine vision. While both are based on image analysis, vision dimensional metrology systems generally are offline or near-line systems, collecting dimensional data points in 2-D or 3-D, analogous to those collected by coordinate measuring machines (CMMs). By contrast, machine vision systems generally are located in-line, snapping images of moving parts for real-time examination of features of interest.

TECHNOLOGY OVERVIEW Today, parts requiring dimensional measurement and inspection are becoming extremely small. Some, on the nanoscale, are built up from the molecular level. These parts are too small for measurement via conventional CMMs because contact probes typically cause enough displacement to prevent accurate results.

As applied, vision dimensional measurement systems image the features to be examined with a digital camera that is driven into position using computer numerical control (CNC) technology, operating much like a CMM. Applied in this way, the focal point of the objective lens is analogous to the center of the CMM’s stylus. A magnification level is determined, the workpiece is illuminated to optimize contrast and an appropriate lens train is selected. The feature of interest is programmed into the system using appropriate software tools such as edge detection or pattern detection. In some systems, auto-focus technologies that correlate depth of field to known Z-axis values can generate 3-D measurements. Because the workpiece view can be magnified to any power, there is virtually no lower limit to the size of features that can be measured, provided that the optics are properly

ILLUMINATION Workpiece illumination is crucial to the function of vision metrology tools. These tools rely on contrast to automatically find edges and light color to resolve color-based features. The three basic types of illumination include stage, through the lens (co-axial) and programmable ring. Stage lighting is simplest and performs much like lighting used in optical comparators. Coaxial lighting is directed to the workpiece through the optical train and is mainly used to illuminate a workpiece surface. Ring lighting is the most flexible. Some ring designs employ halogen/ fiber optic illumination; others use LEDs. For example, rings can make use of red, green and blue LEDs, mixing the colors to obtain white light. A choice of colors makes it easier to defi ne edges and textures and to distinguish colored features. Color and intensity of light can be programmed by quadrant.

STREAMING VISION Streaming vision is a new technology that in certain applications can greatly impact the throughput of vision metrology. Streaming replaces conventional digital cameras and associated lighting with stroboscopic

Reprinted from Quality, Copyright October 2008

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June 2008 www.qualitymag.com

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GE’s CT Line Enhances Capabilities with Hexagon Agreement WUNSTORF, GERMANY—The phoenix computed tomography (CT) line of GE Measurement & Control Solutions has significantly enhanced its marketing capabilities by entering into a commercial cooperation with Hexagon Metrology (Surrey, UK), one of the world’s largest metrology groups. This collaboration will see the first computed tomography system introduced into Hexagon Metrology’s key industry segments within the next few months.

Hexagon Metrology is part of the Hexagon AB Group and includes leading metrology brands such as Brown & Sharpe, Leica Geosystems and Leitz. It has a global installed base of coordinate measuring machines (CMMs), portable measuring systems and handheld instruments, as well as tens of thousands of metrology software licenses. GE sees the collaboration as an ideal match, marrying its expertise as a technology leader in industrial and health-

care computed tomography with Hexagon Metrology’s strong presence in a wide range of industrial sectors, its metrology knowhow and its market-leading software. “With its global sales network and its metrology application expertise, we believe that Hexagon Metrology will greatly help to boost the use of computed tomography in industrial metrology,” states Juan Mario Gomez, general manager of radiography, GE’s Measurement & Control Solutions business.

Mecnov NDT Systems Acquires Contour Dynamics

Mecnov will operate its new, fullyowned subsidiary under the name of Contour Dynamics Inc. and plans to transfer operations from the current location to a new facility, to be located in Wichita. Kevin Simkins, former president of Contour Dynamics, will remain in charge of the operations.

forms of NDT, which include film radiography, positive material identification, remote visual inspection, magnetic particle testing, penetrant testing and hardness testing. AIT also provides welding engineering services, such as welding program development, weld procedure development and qualification and project management. “We at Spitzer are excited to have AIT as part of our team and look forward to taking our combined talents to current and potential customers,” says Cullen Spitzer, chief executive officer of Spitzer. “We have been working diligently over the past months trying to strengthen our capabilities with respect to welding technology and welding engineering. With the acquisition of AIT, we now have a more complete portfolio of services to offer our customers and look forward to providing expanded product lines, state of the art technology, engineering and NDE services to our clients.” “From AIT’s perspective, we are pleased to expand the advanced NDT services that we provide into Spitzer’s fabrication facilities,” says Jim Halley, co-founder of AIT. “It’s a perfect fit—world-class fabrication and advanced NDT. Incorporating advanced NDT into fabrication as a means of process control helps to ensure that the specialized equipment manufactured by Spitzer will perform as expected in some of the most challenging environments in the world. We are excited to be part of the Spitzer team and look forward to helping Spitzer to continue setting themselves apart from their competitors.”

LEVIS, CANADA—Mecnov, a provider of industrial-strength automated nondestructive testing (NDT) solutions, announced it has acquired all the assets of Contour Dynamics Inc. (Wichita, KS). The transaction confirmed that Mecnov will receive all intellectual properties of Contour Dynamics, including motion control software, trademarks and technological know-how, as well as works-inprogress and accounts receivable from active contracts. Contour Dynamics is a privately-held company established in 2001. The company has been recognized for its expertise in multiaxis, automated, ultrasound inspection scanners for mission critical structures and parts of advanced composite materials used in aerospace applications. Kennedy Gagnon, president of Mecnov, hailed the acquisition as an opportunity to allow the company to accelerate its expansion and market diversification. “Over the years, Contour Dynamics has delivered reliable automated NDT systems to numerous customers,” Gagnon says. “It has a complementary product portfolio and is greatly respected within the industry. The high level of customer satisfaction enjoyed by their clients, which reflects a similar scale by which Mecnov judges its success, made this transaction an ideal fit for both companies. Our immediate objective is to commit the necessary resources to further grow the business.” 6 NDT ● APRIL 2011

Spitzer Completes Acquisition of AIT HOUSTON—Spitzer Industries Inc. announced the completion of its acquisition of Advanced Inspection Technologies (AIT, Houston). AIT specializes in performing advanced nondestructive testing (NDT) of welds and base materials, using phased array ultrasonic testing and computed radiography. The acquisition also furthers Spitzer’s fabrication capabilities with deeper welding engineering and technology capabilities. AIT was founded in March of 2003 by Michael Beard and Jim Halley with the primary focus of developing automated ultrasonic testing equipment and procedures necessary to compete for contracts within the nuclear, power and energy sectors. AIT serves a broad customer base within these sectors as well as the petrochemical, refining, aerospace, and offshore oil and gas industries. AIT performs inspections using automated, semiautomated and manual systems and techniques using phased array ultrasonic testing of welds, vessels and forgings. AIT also performs conventional

NDT SPECIAL SECTION

www.ndtmag.com

Michael Beard, co-founder of AIT, says he is excited about returning to fabrication and working with Cullen and the team at Spitzer. “Integrating the services AIT has been known for into Spitzer’s manufacturing facilities will give us a competitive advantage by offering state of the art services that no other fabricator in the industry can offer,” he says. “With my experience and background in welding engineering and welding technology, I will be working with the Spitzer team to expand our services in NDE and fabrication in support of critical fabrications for offshore oil and gas and the nuclear industry.”

PAG Adds NDT Certification and Capabilities ATLANTA—Precision Aviation Group (PAG), exclusive provider of inventory supported maintenance repair and overhaul (ISMRO), announces that its subsidiary, Precision Accessories and Instruments (PAI) has been awarded nondestructive testing (NDT) certification by the FAA. PAG has MRO shops for accessories, avionics, hydraulics, instruments, NDT, starter/generators and wheels/brakes. With 90,000 square feet of facilities in Atlanta, and Vancouver, BC, unlimited FAA ratings for accessories, avionics and instruments, PAG provides tier-one MRO and supply chain services 24 hours a day, 365 days a year.

ing to team member Stephen Langer, version 2.1 is the first dramatic extension of the original capabilities of the software. Jet turbine blades, for example, can spin more efficiently with a layer of ceramic material sprayed onto their surfaces, but the ceramic layers are brittle. Knowing how these ceramic layers will respond as

S1 TURBOSD Technology you can trust

the metal blades heat up and expand over time is one of the many problems OOF 2.1 is designed to help solve. Later this year, the team expects to enable users to analyze three-dimensional (3-D) micrographs of a material, rather than the two-dimensional (2-D) “slices” that can be analyzed at this point.

s Positive material identification s Fast alloy ID and chemistry s Completely non-destructive s Light element analysis without He or vacuum

NIST Expert Software Lowers the Stress on Materials Problems GAITHERSBURG, MD—Computer scientists at the National Institute of Standards and Technology (NIST) have improved software that can take much of the guesswork out of tough materials problems. The software package, object-oriented finite (OOF) element analysis, is a specialized tool to help materials designers understand how stress and other factors act on a material with a complex internal structure, as is the case with many alloys and ceramics. As its starting point, OOF uses micrographs—images of a material taken by a microscope. OOF has been available in previous versions since 1998, but the new version (2.1) that the NIST team released in February, adds a number of improvements. Accordwww.ndtmag.com

The S1 TURBOSD XRF analyzer uses innovative SDD technology which provides fast and accurate alloy analysis. www.bruker.com/hhxrf [email protected]

Innovation with Integrity

NDT SPECIAL SECTION

Handheld XRF

APRIL 2011 ● 7 NDT

The Evolution of the NDT Quality Inspector Quality should be determined by the intended technicians, clients or customers, and not by society in general.

By Joseph Sorrentino

8 NDT ● APRIL 2011

The absence of trained nondestructive testing (NDT) quality professionals—whose mission in life is to protect their organization’s integrity, reputation and liability—is visibly evident in many of today’s companies. This trend is due mostly in part to the growing popularity of lean and Six Sigma. I can understand why organizations fear the NDT inspector, who is always looking over someone’s shoulder with hopes of finding mistakes to justify his existence. However, this scenario does not ring true in all cases. In fact, human survival instincts will dictate that if an NDT inspector, or any employee for that matter, identifies a red flag—for example, the purchase of their company as bolt-on resource for a larger organization—this will drive that employee to justify his position. As humans, we tend to act irrationally when we are in survival mode. For an NDT inspector, this could mean overestimating the impact of system, process or product nonconformities on an organization, which could ultimately result in a loss of inspector credibility. I recently came across this job description while I was with a client: “The NDT quality inspector will inspect parts as directed by engineering directives and the quality/production manager and will identify, record and process identified nonconformities using tools, such as root cause, corrective actions, continuous improvement, internal audits, and other measurement and analysis techniques as applicable. The inspector will be trained in and understand statistical techniques, such as statistical process control (SPC), cause and effect, Six Sigma and standard deviation as applicable to meet the needs of the customer, organization, regulatory and statutory requirements.” There are many things wrong with this job description that could be another article in itself. If I had my way, I would eliminate terms used to describe positions in organizations, such as quality manager, quality management and quality inspectors. The word quality is an ambiguous term with many meanNDT SPECIAL SECTION

ings. Quality should be determined by the intended technicians, clients or customers, and not by society in general. Even goods with low prices can be considered quality items if they meet a market need. As many international standards have recognized the challenges of globalization and the open world outsourcing markets, it is time that we not only revise our management systems, but our custodians of these changes—the NDT inspectors. This same globalization also has produced the need to redefine what was once known as a quality manager. In the revised international standards, such as ISO 9001: 2008, the rationale and the shift from quality requirements to customer and organization, regulatory and statutory requirements as the foundation of the mission target of all organizations is visibly evident. The mission target is always to meet the big four—customer, organization, regulatory and statutory requirements. So where do quality assurance or quality inspectors come in as part of this scenario? They don’t. I welcome your feedback and comments regarding the evolution of today’s NDT quality inspectors and the impact of globalization on the role of quality management in today’s companies. Joseph Sorrentino is president and CEO of Lean Quality Systems Inc. (Dana Point, CA). You can reach him at [email protected].

NDT BUSINESS CARDS These easy-to-use cards are a handy and low-cost way to reach NDT and material test buyers.

Sunny Coverly P: 610.932.8350 • F: 248.283.6587 [email protected] www.ndtmag.com

Hardness Testing 101 Consider ultrasonic contact impedance for nondestructive inspection of components. By Sat Kumar Hardness testing is one of the most popular, reliable and yet diversified material testing methods. Most hardness testing is performed by using the Rockwell, Brinell or Vickers method. When selecting the correct method there are a number of criteria to be considered, including test load, hardness scale, accuracy of results, adaptability to specimen shape, budget and portable or tabletop configuration. The ultrasonic contact impedance (UCI) method allows operators to test the hardness on large or small components at various locations. It can be used to make hardness measurements on positions difficult to access, such as tooth flanks or roots of gears. The testers that adopt UCI technology provide quick and precise measurements of metal hardness, plated coating (chrome) and mechanical strength estimation. The UCI method hardness testers provide the hardness ranges of main hardness scales, such as HB, HRC, HV, as well as HRA, HRB, HSD scales and tensile strength. When using the UCI method, the diagonals of the test indentation, which have to be known in order to determine the Vickers hardness value, are not evaluated optically, but the indentation area is electronically detected by measuring the shift of an ultrasonic frequency. A UCI probe typically consists of a Vickers diamond indenter attached to a metal rod, which is subjected to oscillation by piezoelectric transducers. After the test load is applied, a frequency shift occurs as the diamond penetrates into the material. This frequency shift will become greater when the test indentation becomes larger, or when the diamond penetrates deeper into soft material. Analogously, the smallest frequency shift is produced by hard test materials; the diamond penetrates only slightly into the material and leaves a small indentation. Thus, the hardness value is deterwww.ndtmag.com

In the UCI method, the diagonals of the test indentation area are electronically detected by measuring the shift of an ultrasonic frequency. Source: Qualitest USA

mined by the frequency shift within seconds. This method of hardness testing is standardized by ASTM A1038. The instrument that uses this technology constantly monitors the frequency and instantly displays the hardness value based on the difference in ultrasonic vibration frequency. Even though the UCI test procedure is slower than the dynamic impact method, it is portable, easy and accurate. UCI testers are not restricted to large mass and these units can test metals as thin as 1 millimeter and at a hardness value as low as 20 HRC (75 HB). They also can perform hardness tests on larger, harder metals, as well. Another reason for the rise in popularity is due to the fact that the UCI

method is categorized as nondestructive. The UCI method is intended not to replace traditional Vickers testing, but rather to complement it with a quick, field portable test method. Additional changeable sensors of different design for measuring in slots, blind holes and in other areas are available from several manufacturers. The tester has a flexible memory for recording results and allows the stored results to be transferred to a PC at a later stage with the help of software. Sat Kumar is marketing manager at Qualitest USA (Plantation, FL). For more information, call (877) 8848378, e-mail [email protected] or visit www. worldoftest.com.

NDT SPECIAL SECTION

APRIL 2011 ● 9 NDT

NDT

PERSONNEL CERTIFICATION 101

Companies looking to certify their employees should follow these steps to certification. By Justin Lehmann

P

Picture this: a company is offered a chance to subPictur mit a request for proposal on a significant, lucrative contract. It reads through the proposal and finds contr contra that h tthe contract requires nondestructive testing (NDT) to be performed. Three options are given: (NDT Turn down the work because the company has no knowledge of NDT; perform the NDT internally; or have a qualified company perform the NDT. Obviously, the first option is not the best choice. In the other situations, a company is responsible for either certification of its personnel or verifying the certifications of the outside agency’s personnel. Often a company will find itself in this position and have no clue how to establish an appropriate program to certify its personnel or verify certification of an outside agency’s personnel.

Shown here are liquid penetrant indications on aircraft landing gear strut. Source: Quality Testing Services

In the past, personnel certification was performed by an expert who trained employees within their facilities. Shortly thereafter, a certificate would arrive in the mail that could be hung on the wall. It looked official and often was adequate for customers and regulators, such as the Federal Aviation Administration (FAA) and the Federal Railroad Administration (FRA). Unfortunately, for the technician and his customer, those certificates may not have met all of the criteria of certification. In fact, the training performed by this expert was most likely only 25% of the requirements for certification of personnel. This is a trend that is evolving.

QUALIFICATION VS. CERTIFICATION Qualification and certification become quite confusing to the novice NDT practitioner, and at first glance, one would think they might mean the same thing. 䡲 Qualification: Demonstrated knowledge and examinations, documented training and documented experience required for personnel to properly perform the duties of a specific job. 䡲 Certification: This is the written testimony of qualifications.

NAS-410 is widely used in the aviation industry. Source: Quality Testing Services 10 NDT ● APRIL 2011

NDT SPECIAL SECTION

After seeing the definitions, it becomes quite clear these are two functions. Qualification is the process of learning and proving how to perform NDT, and certification is just the documentation that was done. www.ndtmag.com

There are many ways personnel are certified to perform NDT throughout the world. There are a few widely accepted ways of establishing personnel qualification and certification in various industries, for example, NAS-410 is widely used in the aviation industry. This article deals primarily with qualification and certification schemes used in the United States. The following gives an overview of the steps required to properly establish a qualification and certification program in a company.

ten practice. Several examples include the American Society for Nondestructive Testing (ASNT) Document—SNT-TC-1A (recommended practice for company-based certification), National Aerospace Standard (NAS) NAS-410 or American Association of Railroads Appendix T (code).

A company must determine which standard is most appropriate for its situation. Notice these are different types of documents. A recommended practice is designed to give a set of recommendations that may be changed, a standard is a set minimum, and a document tied to a code

EMPLOYER-BASED CERTIFICATION Review contract documentation: Contract documents should be reviewed to determine how the NDT personnel are to be qualified and certified. The documents should include some reference, such as “Personnel performing ultrasonic testing shall be qualified and certified in accordance with SNT-TC-1A.” When such wording is absent, the discrepancy should be cleared up with the customer and the contract documents amended. When the customer chooses to remain silent on such matters, the NDT company should keep in mind that if any litigation arises from this work or subsequent operation, if they have performed their work with due diligence, it will be a good reflection on them. Establish written practice: The procedure ought to be written to comply with one of several documents designed to help guide the company in designing the writ-

TECH TIPS ● Contract documents should be reviewed to determine how the NDT personnel are to be qualified and certified. ● The employer may certify the candidate to the appropriate level upon successful completion of the training, experience and examinations. ● NDT personnel qualification and certification should be performed in accordance with the company’s written practice document.

www.ndtmag.com

NDT SPECIAL SECTION

APRIL 2011 ● 11 NDT

administering examimeans it is tied to a law. This nations to Level I and II procedure may be authored personnel, maintaining by the company or by a certification records and qualified outside agency. establishing techniques and Employ an NDT Level procedures. Some of these III: The standards described duties may be delegated by above require NDT Level the responsible Level III. I, II and III personnel be Qualify Level I and certified by the employer. II personnel: Candidates Level I technicians are only must have adequate educaqualified to execute certain tion, training and experitests and calibrations, while ence in order to qualify for Level II technicians are Level I, II or III certificaqualified to set up and calition. A company Level III, brate equipment, conduct a qualified instructor or a the inspection according to It is important that the technician be qualified in the inspection qualified outside agency, procedures, interpret, eval- method before the technique is used and test results evaluated. must perform the training. uate and document results Source: Qualified Testing Services The general examiin all the testing methods For economic reasons, an employer nation for Level I and II covers NDT used by the certificate holder, according to the NDT Resource Center. Level III may opt to use a qualified outside agency method theory, principles and applicatechnicians are responsible for the train- Level III rather than employ a full-time tions. The specific examination tests the ing of both Level I and II technicians and Level III. The standards described above candidate’s knowledge of company prorequire a Level III to be responsible for cedures, techniques and specifications may act as a supervisor or consultant.

12 NDT ● APRIL 2011

NDT SPECIAL SECTION

www.ndtmag.com

Employer certification of Level I or II personnel: The employer may certify the candidate to the appropriate level upon successful completion of the training, experience and examinations. The employer must keep records of qualifications, examinations and certifications on file. An outside agency can only provide Level III services—certification is the responsibility of the employer. Certifications are normally valid for a period of three or five years, depending on the document that their written practice was meant to comply with. Near vision exams must be performed on a yearly basis. As an employer, or one who is responsible for personnel who perform NDT, be aware of the company’s responsibilities: 䡲 Written practice. 䡲 Certification and qualification of personnel. 䡲 NDT procedures. 䡲 Each of the above must be approved by a Level III. 䡲 The employer should have an individual who is responsible for their NDT program. This person must be a Level III in the respective NDT method. 䡲 Level III services can be provided by a company NDT Level III, or outside agency NDT Level III service company. www.ndtmag.com

NDT personnel qualification and certification should be performed in accordance with the company’s written practice document. Qualification consists of primarily three things—training, experience and testing. Certifications and records must be kept up-to-date. NDT

Justin Lehmann is director of training and consulting at Quality Testing Services Inc. (Maryland Heights, MO). For more information, call (314) 770-0607, e-mail [email protected] or visit www. qualitytesting.net.

©2010 Thermo Fisher Scientific Inc. All rights reserved.

commonly used. The practical examination demonstrates the candidate’s ability to perform the NDT method and evaluate the results. The candidate also must pass a vision examination, because it is essential that NDT technicians have accurate near sight and color vision. In addition, these exams are required to be administered by a Level III. These minimum requirements are detailed in the company’s written practice or Procedure for Qualification and Certification of NDT Personnel. For example, a magnetic particle Level II candidate must have: 䡲 Examinations—General, specific and practical exams are required. 䡲 Training—32 hours of documented classroom training in magnetic particle inspection by a qualified instructor. 䡲 Experience—530 hours of experience under the supervision of a certified Level II or III.

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Moving science forward

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APRIL 2011 ● 13 NDT

Cracking Down on

DEFECTS

Advanced techniques can be used to visualize defects in welds. By Dan Kass

E

Ensuring the integrity of joined materials is always Ens paramount in delivering quality and safety in both para structural members and manufactured compostr stru nents. Ultrasonic inspection has long been used as nen primary nondestructive test (NDT) method for a pr a va variety of weld and bonding processes. Selection of a range of frequencies and modes of sound propagation allows testing a variety of materials, including metals, plastics and composites over a broad range of thickness and joint configurations.

This is a selected A-scan with 40 to 70 degrees sector scan image displaying scattered indications from weld porosity. Source: Olympus NDT 14 NDT ● APRIL 2011

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Conventional ultrasonic flaw detection using small, handheld instruments with single element transducers is well-established as a quality control technique in many manufacturing and service industries. In recent years, there has been growing interest in phased array systems that use sophisticated technology based on multi-element probe assemblies to generate steered beams and create cross-sectional pictures similar to those in medical ultrasound imaging. These instruments also are commonly used for industrial inspections.

HOW IT WORKS The technology of ultrasonic flaw detection is based on a simple principle of wave physics. A high frequency sound wave that has been launched in a solid medium, such as steel, will travel in a straight line until it encounters a material boundary—a far wall, another material interface or a hidden crack. At that point, the sound wave will be reflected and/ or diffracted in a predictable way. Ultrasonic flaw detectors generate short bursts of sound energy through small, handheld probes that are coupled to the surface of the test piece. The instrument then displays the pattern of sound reflections, which will change as material conditions change. Sound waves in solids vibrate in various modes of propagation that are defined by the type of motion involved. Longitudinal waves and shear waves are the most common modes employed in ultrasonic flaw detection. Surface waves and plate waves also are used on occasion but are far less common. Longitudinal waves are characterized by particle motion parallel to the direction of propagation and are typically used for locating voids, porosity and cracks or delimitations parallel to the outside surface of a part, as well as for measuring thickness. www.ndtmag.com

An ultrasonic flaw detector with angle beam probe inspects a V-welded plate. Source: Olympus NDT

A shear or transverse wave is characterized by particle motion perpendicular to the direction of wave propagation. Shear waves travel at a slower acoustic velocity and thus present a shorter wavelength, increasing resolution as compared to equivalent compressional wave frequencies. Shear waves are generally produced using angular offset via a polystyrene wedge.

WELD INSPECTION Ultrasonic testing of structural welds is used to check penetration depth and detect lack of fusion, toe cracks, root cracks, as well as porosity or slag inclusions. Weld configurations are varied, including butt welds, lap welds, T-welds in plate and seam welds in piping. Cracks or other discontinuities perpendicular to the surface of a test piece, or tilted with respect to that surface, are usually invisible with straight beam test techniques because of their orientation. An angle beam assembly directs sound energy into the test piece at a selected angle. A perpendicular crack will ref lect angled sound energy along a path that is commonly referred to as a corner trap. www.ndtmag.com

In particular, inspection procedures generally specify use of primary inspection angles of 45, 60 and 70 degrees with at least one angle matched to the bevel of the weld. For these inspections, the probe is moved forward to inspect in the first leg for ID connected cracking and lack of penetrations. The probe is then moved backward to create a skip off the back wall for inspection in the second leg along the bevel and top of the weld. To achieve full volumetric inspection of the weld, the operator must continue to move the probe along the entire weld length in a raster scan pattern. Skewing the probe also is required to help identify and distinguish flaw type. The echo-dynamic from a planar flaw such as lack of sidewall fusion or cracking is very directional and will fall off sharply when the transducer is skewed. Multiple small reflectors such as porosity or inclusions will have a ragged multiple peak amplitude response which is more constant as the probe is moved. There are numerous methods for flaw sizing, but all require comparing echo amplitudes to a calibration reflector. Flaw boundaries often can be recorded by scanning along the length of the flaw

and marking the amplitude envelope as the sound beam is moved. Flaw depth is calculated using trigonometry to convert angular sound path to distance from the front of the probe and depth. This calculation is displayed in real-time in today’s digital flaw detectors. Generally, higher frequency probes are required as the parts get thinner. As parts get thicker, not only are lower frequency probes required, but it is often necessary to inspect the weldment in zones, using a variety of probe angles and frequencies. While shear wave inspection works well in ferritic steels, austenitic and coarse grain materials are very attenuating. For these anisotropic materials, the velocity varies with angle making it difficult to perform through wall sizing. In these cases refracted longitudinal wave transducers are used, particularly in cases where through wall sizing is required. To maintain resolution in this longer wavelength approach, twin crystal probes with a compound angle wedge are used to focus the beam at appropriate inspection depths.

PHASED ARRAY Advanced techniques can be used to visualize defects in welds. One such approach simply arranges angle beam probes on either side of the weld in an encoded scanning fixture. Amplitude and

TECH TIPS ● To achieve full volumetric inspection of the weld, the operator must continue to move the probe along the entire weld length in a raster scan pattern. ● Phased array instruments work with multi-element probes that are individually pulsed and time-delayed. ● Brazing is a common process for joining sections of small diameter metal tubing and certain other small metal parts such as electrical contacts.

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APRIL 2011 ● 15 NDT

time responses are recorded along with transducer position to produce a map from each probe. The need to manage multiple probes, however, makes the setup complex. Phased array instruments work with multi-element probes that are individually pulsed and time-delayed. Beam steering allows one transducer to generate an image from a sequence of angles (sector scan) or to produce an image of a fixed angle that travels over the length of a probe (linear scan). For manual weld inspection, a 40 to 70 degree sector scan is commonly used. Simultaneous live inspection across a range of angles inclusive of the primary angles specified for conventional ultrasonic testing enhances probability of detection. The sector scan aids in differentiation of flaws from weld geometry and eases identification of flaw types. The height of ID connected cracks can be estimated from the image data directly. A weld overlay is commonly generated as part of the image to help place flaws within the weld volume. When using a linear array, a fixed angle can be swept forward and backward from the weld electronically. Moving the probe along the length of the weld increases inspection speed. Using phased array probes as part of an encoded scanning fixture significantly reduces the number of probes required, and hence, reduces complexity of automated systems.

BOND INSPECTIONS A variety of manufactured components are joined together via welding or adhesion procedures. When these interfaces are parallel, a longitudinal wave probe can be used. Brazing is a common process for joining sections of small diameter metal tubing and certain other small metal parts such as electrical contacts. It bonds two pieces of metal by means of metallic filler through a capillary process. If the braze metal does not flow properly or does not fuse, the integrity of the joint will be affected. The transducer should be selected with respect to the geometry of the specific joint being tested. Frequently small diameter, high-frequency delay line transducers are recommended. As discussed previously, visualization of bond integrity of similar materials can be accomplished from an encoded C-scan image generated mechanically along two axes or with phased array using a linear array probe encoded in one direction. This C-scan image presents a planar map of defects at the bonded region. While bonding of similar materials is easily identified through signal reflection at the boundary, when the two bonded materials differ greatly in acoustic impedance, such as a plastic to metal bond, the change in the amplitude of reflected signals

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Shown here is a ring down pattern from metal to plastic bond. (Top) This is a slow ring down pattern from disbond. (Bottom) This is a fast ring down from bonded region. Source: Olympus NDT www.ndtmag.com

between good and bad bonds is less a 25% drop at the fifth echo and dramatic. In these cases, the most a 50% drop at the tenth echo. readily visible difference between While the change in a single bonds and disbond is a reversal in echo may be small, the collecthe phase or polarity of the echo tive change across a series of from the boundary. This phase multiple echoes will be much shift will occur whenever a matelarger and easier to identify. rial of low acoustic impedance such In a typical joint, bond and as plastic, composite, fiberglass, disbond conditions will each rubber or epoxy is bonded to high produce their own distinctive acoustic impedance materials such ring down pattern. as metal, glass or ceramic. Ultrasonic shear and longituIn cases where the test must dinal wave inspection techniques be performed from the high A scanning fixture using phased array probes to produce are well proven NDT methimpedance side of the joint, a ring single line full volumetric scan of circumferential weld ods applicable to a variety of down technique can be used. This for later review. Source: Olympus NDT joined material configurations. involves observing a series of mulAvailability of industrial phased tiple reflections from the boundary and looking for a difference array instruments often can reduce complexity of volumetric in the rate at which the amplitude of successive echoes, or the inspection and aid in defect visualization leading to improved ring down envelope, changes between bond and disbond con- probability of detection. NDT ditions. As the sound wave reverberates in the metal or other high impedance material, the amplitude change is multiplied Dan Kass is the portables technology specialist at Olympus NDT (Waltham, MA). For at each bounce. For example, a hard-to-see 5% amplitude drop more information, call (781) 419-3900, e-mail [email protected] or visit between disbond and bond conditions at the first echo becomes www.olympusndt.com.

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APRIL 2011 ● 17 NDT

COMPUTED RADIOGRAPHY: Keep it Short Implementing a computed radiography program will help overcome economic and environmental challenges. By Larry Culbertson, Clyde May and Greg Pupchek

I

Industrial radiography, also known as X-ray inspecIn tion, is being continuously challenged to adequateti ly replace conventional standardized film methods with w computed radiography (CR). Radiography is one of the oldest nondestructive inspection metho ods used in various stages of manufacturing, fabrio cation and preventative maintenance programs for initial defect detection, corrosion monitoring and product conformity. The adage “A picture is worth a thousand words” refers to a concept that at a complex idea can be conveyed with a single still image. This adage achieves eves the main goal of visualization, n, specifically making it possible to absorb large amounts of data quickly in a single view. In nondestructive testing (NDT), we have historically used an analog image (film/ radiograph) to be worth a thousand words. Now technicians ns can call this dynamic and prized zed possession a digital radiograph. This method of inspection n has many inherent challenges that the seasoned film radiographer must be aware of, and if not addressed properly, these conditions can be detrimental to the overall inspection results. The characteriza-

18 NDT ● APRIL 2011

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tion and evaluation of this image requires additional training, over and above current requirements found in SNT-TC-1A, NAS 410 and CP-189 for the typical industrial radiographer. CR, as defined by ASTM E1316 (photo stimulated luminescence method), is a two-step radiographic imaging process. First, a storage phosphor imaging plate is exposed to ionizing radiation. Second, the luminescence from the plate’s photostimulable luminescent phosphor is detected, digitized and presented on a high-resolution computer screen. Managing this process, with the objective to achieve the optimum digital image, is the challenge faced by radiographic practitioners. The overall success is based on the digital image acquisition system utilized and variables that are consistent with typical radiographic conditions. Implementing CR begins with a fundamental understanding of the radiographic prinhave been practiced for decades ciples that hav with film radiography and commissioned by the aerospace, automotive, construction, energy, oil tive and gas, and shipping indusan tries. Certified radiographers tr aare required to understand tthese principles, along with sspecific knowledge in the manufacturing and fabricam tion process to correctly intertio pret the acquired digital image. pre Geometric principles attributed to Geom the setup are critical in the evaluation mechanical or fatigue failure of hidden m and for assessment of repair work. The utilization of the proper image quality indicators (IQIs) to ensure technique validation and contrast sensitivity, along with resolution, www.ndtmag.com

and Simple This is a CR Image (X-ray) of an aircraft structure 14 inches wide by 52 inches long. Source: Virtual Media Integration

optimize sensitivity and resolution by using the lowest energy possible, thereby maximizing contrast and leading to longer exposure times. This approach is being debated routinely, as longer exposures have tendencies to saturate (overexpose) the imaging plates. Successful results have been obtained on thicker components using CR with significantly lower radiation doses from reduced exposure time.

STEP 2: IMAGING PLATES

Shown here is an example of a typical aerospace X-ray lab application. Source: Virtual Media Integration

is both essential and mandatory based on most industry specification and code compliance. Integration of an operator defined quality control program to monitor equipment performance and maintain records of data collected is essential to ensure a stable continuous process. System and scanner performance tests will vary from manufacturer to manufacturer but must include those quality control checks specified by the manufacturer and be modeled to meet the technician’s requirements. If, at the time of inspection, significant equipment malfunctions are found, the technician may be required to perform more frequent testing to ensure good image quality. www.ndtmag.com

STEP 1: SETUP Geometric parameters such as source-tofilm distance (SFD) and object-to-film distance (OFD); as well as IQI, area of interest, scatter and alignment are variables that remain similarly consistent as experienced in film radiography. Items that require attention with a greater appreciation for the acquisition of the digital image pertain to the secondary scatter of the technique, knowing the inherent characteristics of the specimen under evaluation, using the correct IQI, optimizing the exposure based on the energy levels and the actual exposure time. T h e r u l e o f t hu m b e x p o s u r e approach—X-ray or gamma—was to

Choosing the proper imaging plate will be dependent on a number of factors, including the scanner that is used, the required resolution, nature of the specimen and quality of radiation energy. The best approach is to ensure that image quality—which is influenced by the scanner and imaging plate system— achieves the quality requirements of the technician.

TECH TIPS ● Imaging plates can theoretically be reused thousands of times if they are handled carefully. ● Processing CR images can be accomplished in subdued light and can be easily adapted to customer locations for onsite processing. ● Contrast and brightness are prominent terms utilized in film radiography and are restated as window and leveling when evaluating digital images.

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APRIL 2011 ● 19 NDT

Sufficient window and leveling with proper filters achieves the optimum image. Source: Virtual Media Integration

The favorable choice would be to use a scanner that accepts both rigid cassettes, as well as the flexible plates since hardware being evaluated may require an imaging plate to conform to its configuration. Imaging plates and industrial film have a commonality in that the latent image is stored and is not visible until processed. The latent image on film is revealed when developed; the latent image on a CR imaging plate is not visible until a CR scanner or reader acquires the image. The need for chemicals to develop a latent image stored on imaging plate is not required. The requirement for multiple films and exposures with film to satisfy a wider range of thicknesses is no longer necessary as the wider latitude is accomplished with CR imaging plates. With film radiography each specific film type was identified by one of four classes, ranging from special through class three. With computed radiography, the same imaging plate could theoretically qualify for all four classes due to the wider dynamic range of computed radiography vs. that of a normal film or screen system. Silver bromide crystals are utilized in the matrix of film, where the latent image is acquired based on the relative exposure to radiation. In CR, a thin phosphor layer of fine-grained barium fluorohalide crystals captures the energy within the phosphor creating a latent image. Short radiographic exposures vs. 20 NDT ● APRIL 2011

long exposures can be compensated by adjusting the signal sensitive parameters of the scanner. The use of lead screens as energy intensifiers in film radiography is now relegated to absorbing scattered soft radiation in CR, as the intensification is not applicable to the phosphor. Imaging plates can theoretically be reused thousands of times if they are handled carefully. Handling under industrial conditions may result in damage after a few hundred uses. Reusable phosphor plates are environmentally safe but need to be disposed of according to local state and federal regulations.

STEP 3: PROCESSING OF THE IMAGING PLATES CR is considered an environmentally friendly process since there are no acids, caustic chemicals or effluents containing heavy metals as required when processing the analog film or radiograph. There is also no longer a need for dark rooms as required in the processing of film. Processing CR images can be accomplished in subdued light and can be easily adapted to customer locations for onsite processing. Typical CR scanners use a laseremitting red light and scan the imaging plate. When the imaging plate is put through the scanner, the scanning laser beam causes the electrons to relax to lower energy levels, emitting light that is detected by a photo-multiplier tube, which is then converted to an electron-

NDT SPECIAL SECTION

ic signal. The electronic signal is then converted to discrete digital values and placed into the image processor pixel map—more ionizing radiation captured in a given region of the imaging plate the greater amount of blue light is emitted. Each pixel intensity value is proportional to the absorbed dose during the exposure. When scanning, there is often a misconception in obtaining the optimum image. The practice of “scan at the highest resolution possible” does not always yield the highest resolution in the acquired image and should be carefully evaluated. Many factors, such as sensitivity, resolution (both spatial and contrast), sharpness, system noise, pixel intensity values and all other parameters specified in the radiographic technique should be considered prior to scanning. The combination of imaging plates, scanner and software used should be classified and documented to ensure repeatability along with image quality. During the processing of the image, the computer applies various algorithms and displays an image on a computer monitor. Erasing the image plate is critical in removing any ghost images from the plate that may interfere with the subsequent image. Erasing an image plate is accomplished by simply exposing the plate to a room-level fluorescent light. Most CR scanners automatically erase the image plate after laser scanning is complete. Achieving the optimum quality image in the raw data form without any post processing and/or a software enhancement converting the image is the key objective that closely represents the film quality that has been accomplished for decades.

STEP 4: POST-PROCESS Evaluating digital images is similar to evaluating film images, as they are required to be viewed in subdued lighting by qualified and experienced personnel. CR’s unique property—as compared to film systems—is the ability to display a wider range of visible gray-scale levels for a defined range of material thickness, particularly when image processing is used. Achieving a good signal-to-noise ratio (SNR) in the area of interest will yield a quality digital image as required www.ndtmag.com

for inspection applications, similar to the contrast and resolution achieved for film images. Contrast and brightness are prominent terms used in film radiography and are restated as window and leveling when evaluating digital images. Window (contrast) and leveling (brightness) adjustments are temporarily assigning different gray values instead of those gray values originally assigned because darker pixels can be lowered in gray scale value while lighter pixels can be raised. This ability allows areas of interest to be optimized for interpretation in single image. Most CR imaging software packages have a range of enhancing abilities, however, no one single filter or combination of filters can produce a magic button for improved image quality. There are many parameters, such as edge enhancements, high pass, sharpen, unsharp mask and many others that compete with each other, and are traded off against each other. An improvement in one parameter can degrade another, resulting in decreased sensitivity and resolution. Achieving a significant sharpness parameter within a digital image, also known as spatial frequency response, will not result in a good image without good contrast-to-noise ratio (CNR) and SNR. Filters applied may increase or decrease these ratios. Analyzing the radiograph for good CNR and SNR and other factors determining image quality can be demonstrated by most software platforms. These critical functions should be evaluated and procedures documented by the cognizant engineer or NDT Level III establishing the CR program. Using a magnifier loupe to evaluate and grease pencils to mark film are no longer required as all CR evaluation stations have these functions electronically and can measure reliably based on an image calibration point. To achieve optimum performance of any CR program, even for the experienced radiographic practitioner, establishing an adequate training program with complete understanding of all post processing parameters is paramount. With all nondestructive inspection programs, operators are required in most cases to establish a quality control program that routinely validates an inspection process. www.ndtmag.com

Using a phantom, a recommended traceable standard, at prescribed intervals allows for routine evaluations of the CR system operation. Parameters for variation with control limits should be documented and agreed on by the

practitioner along with the technician. Phantom process verification can be accomplished by contrast, spatial resolution/unsharpness, converging line pair, geometric distortion, laser beam function and laser jitter, scan line integ-

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APRIL 2011 ● 21 NDT

rity, blooming or flare, slippage, shading, erasure, IP artifacts and SNR.

software unless a proper data file protocol is established by the end user.

STEP 5: FINAL AND FILE

TAKE CHARGE

Final acceptance of the image is the same as film radiography and is the responsibility of the certified technician. Reference radiographs for defect severity and comparison are being updated to digital formats for ease of interpretation. Preserving the raw image is critical and maintaining its origin is a requirement by most industry codes, specifications and end users. It is the operator’s responsibility to maintain this data set to ensure recall in the original format as needed. Post-processing enhancements, along with annotations, are required to be traceable to the original raw data file. Film packages, missing film, storage damage that were film related issues will now be lost images, damaged files, files that cannot be opened due to outdated

Is computed radiography the complete film replacement at this time? Is there one nondestructive examination that achieves 100% defect detection? Is ultrasonic phased array better than all other conventional ultrasonic techniques? The answer by experienced NDT practitioners would be unanimously no. All nondestructive inspection modalities have their inherent abilities and some prove to be better than others. CR has improved significantly and should be credited for enhanced radiographic process, environmentally compliant, reduced radiation exposures, cost effectiveness over time and improved communication with today’s digital tools. The continued excuses such as resistance to change, cost to implement, low com-

puter skill sets, lack of specifications, lack of training, perceived detection limits and associated factors are impeding the transition from film radiography to CR. With the economic and environmental factors alone, the cost of film radiography is positioned to escalate. Implementing a CR program with solid fundamental practices, a commitment to integrity, along with a solid training program, will overcome these challenges. This same blueprint of practical perseverance was implemented when film radiography was first introduced decades ago. NDT practitioners must now step up and take charge. NDT Larry Culbertson is director and NDT Level III, Clyde May is director and Corporate Level III and Greg Pupchek is president and director of digital radiography at Virtual Media Integration (Pensacola, FL). For more information, call (850) 432-0355 or visit www. starrview.com.

Shape the Future with an ASNT NDT Level II Certificate • Designed for NDT personnel whose jobs require certification in particular methods. • Provides standardized level II written examinations that employers may use to satisfy the General and Specific examination guidelines of Recommended Practice No. SNT-TC-1A. • Employers can complete the certification process by administering job-specific practical examinations. • ASNT NDT Level II offers employers an efficient option for personnel certification.

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22 NDT ● APRIL 2011

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The Latest in XRF Analysis With its relatively low cost and speedy, accurate measurement capabilities, XRF analysis is as relevant as ever. The newest wave of handheld XRF analysis devices promises real-time results and lightweight design. By Genevieve Diesing, Associate Editor X-ray fluorescence (XRF) is a powerful tool ideally used in elemental analysis and chemical analysis. XRF measurement tools can analyze thickness and composition by determining the weight of solids and solutions and identifying specific and trace elements within samples. XRF analysis is a popular form of measurement and is used in industries, such as metal finishing and refining, semiconductors, telecommunications and microelectronics. Because XRF can carry out noncontact, nondestructive tests quickly and accurately and has a relatively low cost of ownership, it remains an in-demand technology. Read on to learn about the latest developments in handheld XRF analysis tools.

Olympus Innov-X’s (www.innovx. com) Delta line is an innovative breed of handheld XRF. It has redesigned its analyzers from to create instruments that are both analytically accurate and rugged enough for most environments. The Delta analyzers have silicon drift detector technology and 200μA X-ray tubes for maximized accuracy and precision. Delta analyzers also are fully industrialized tools, and their testing speeds yield significantly increased productivity and throughput for operators. This line can be upgraded to a premium model while marinating the same hardware platform and operator interface. They also feature true hot-swap battery capabilities; fast measurements for high throughput; and redesigned geom-

Delta analyzers also are fully industrialized tools. Source: Olympus Innov-X www.ndtmag.com

etry for outstanding analytical performance, speed and lower detection limits. The line also has an auto-calibrating, auto-charging docking station.

QSX Instruments (www.quickshotxrf. com) has unveiled its newest handheld analyzer using XRF technology with nonisotope-based features. It is simple to navigate and offers real-time results on its touchscreen PDA. When the operator

The QSX handheld analyzer offers realtime results on its touchscreen PDA. Source: QSX Instruments

gets back to the laboratory, those results can easily be transferred to a desktop computer for long-term storage, analysis and report generation. The lowest priced handheld XRF available includes a software package, back-up batteries, durable carrying case and warranty. The initial application that this system was developed for is hazardous substance analysis and it exceeds the requirements of restriction of hazardous substances (RoHS) and consumer product safety improvement act (CPSIA) regulations with detection limits down to 10 parts-per-million. Various software packages also make it a portable solution to precious metal analysis and positive material identification. The S1 Sorter from Bruker AXS (www. bruker-axs.com) hides state-of-the-art technology beneath a tough shell. The standard calibration covers steel, nickel, cobalt and copper alloys, while the

optional frontal projection (FP) calibration will analyze most exotic alloys and precious metal samples. It is designed to be used out in the field, in temperatures ranging from -10 C to +50 C. The splash-proof case is made of industrialstrength plastic. The bright display makes it easy to read in any lighting conditions. The touch screen means The S1 the entire machine can Sorter can be be manipulated with one manipulated with one finger. finger, whether inputting Source: Bruker AXS a password or pulling the trigger. The operating system is Microsoft Windows and data transfer options include Microsoft ActivSync via a USB cable or wireless Bluetooth connection, as well as using an SD card. Built-in memory also makes it possible to store thousands of spectra and millions of results safely.

Skyray XRF’s (www.skyrayxrf.com) handheld Pocket-III was designed for comfort, durability and accuracy in measurement. The Pocket is one of the lightest handheld instruments on the market; designed for comfort in the field. It utilizes a 6 millimeter collimator that is focused by design and eliminates any potential for improper sample alignment. It is most popular for hazardous substance testing and it reads below the required parts per minute levels. There are no isotopes utilized in this system. It utilizes Bluetooth technology, downloads to the desktop CPU and has a battery life of more than five hours. There is no shape or size limit for samples, which can be in solid, liquid or powder form. The measurement times range from 10 to 200 seconds and rental units are available.

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Acoustic Pulse Technology Streamlines Inspection AcousticEye’s acoustic pulse reflectometry (APR) technology allows GMA to provide faster and more complete inspections and problem diagnosis of tube systems. GMA, an integrated service company headquartered in Staranzano, Italy, is known worldwide for its expertise in inspecting and maintaining condenser tubes across a wide range of industries. Customers rely on the service provider for mechanical cleaning of condensers and retubing of all types of condensers and heat exchangers. GMA has more than 30 years of experience in the field of anticorrosion, a team of distinguished technicians and specific expertise in polymeric coatings. It is crucial for GMA to be able to offer and provide its customers with service methods that are cost-effective, minimize outage times and increase the efficiency of tube-based equipment. To meet these needs with a complete package of problem analysis and customer-specific solutions, GMA sought an easy, comprehensive and fast inspection solution. The search for such a system resulted in GMA’s discovery of the AcousticEye (Santa Clara, CA) Dolphin tube inspection technology. AcousticEye’s acoustic pulse reflectometry (APR) technology allows GMA to provide faster and more complete inspections and problem diagnosis of tube systems than was previously possible. The result measurably reduced customer downtime and identified problems that were formerly not detectable.

BENEFITS ● AcousticEye’s APR technology inspected 100% of its test of 600 tubes within four hours, a fraction of the time of other inspection methods. ● The AcousticEye Dolphin performed accurate testing in physical locations testable only with APR technology. ● All the data found with the AcousticEye Dolphin was found to be consistent with the laboratory findings. 24 NDT ● APRIL 2011

APR technology detects corrosion and severe pitting in tubes in an Italian refinery, pictured here. Source: GMA

“[AcousticEye] allows us to move in fast during the shutdown and perform the condenser inspection in a fraction of the time it would take to test the tubes with other conventional NDT technologies,” says Roberto Grassetti, CEO of GMA. “We can get an immediate indication of the condition of 100% of the tubes, thus allowing for quick decision making.” “Facilities such as refineries and power companies are excited to find that tubes that were historically nonconducive to inspection are now testable, thus improving efficiency of mission critical equipment,” he adds.

SPEEDY AND ACCURATE During a scheduled maintenance outage at one of GMA’s power generation customer sites, a pressure test revealed two leaks in a carbon steel reheater dryer with u-tube bundle. Due to the geometry

NDT SPECIAL SECTION

of the bundle and the tube material, the tubes were difficult to test with traditional sample-based inspection methods. Using AcousticEye’s APR technology, the entire 600-tube inspection task was completed with 100% test coverage within four hours, including setup time and final analysis. The AcousticEye Dolphin confirmed the presence of two holes which were located in the bend area of the u-tube, a physical location testable only with APR technology. In addition, the inspection revealed an additional five tubes suffering more than 80% wall loss. Although the tubes had been cleaned with pressurized air, fouling was still found to be present in a large percentage of the tubes. As a result of the speed of the inspection with AcousticEye and the accuracy of the leak detection, the GMA team was asked to perform an additional inspecwww.ndtmag.com

impressed with how consistion on three identical dryer tent the defect types, position reheaters with a total of 1,861 and sizes were compared with tubes by the end of the outage in the actual findings from the four days time. An additional 18 destructive test control. tubes were found to have more “Facilities such as refinerthan 80% wall loss, and were ies and power companies are plugged as a result. excited to find that tubes that The APR test proved to be were historically nonconduaccurate and fast, and the cuscive to inspection are now testtomer was able to detect the able, thus improving efficiency defects and plug the tubes withof mission critical equipment,” in the limited timeframe of the says Grassetti. “Since we have shutdown. started offering tube inspection At an Italian refinery, GMA with AcousticEye, our customers tested 302 tubes with the Acousare turning to us more for other ticEye Dolphin for holes, block- APR technology performs fast detection of leaks and ages and pitting thresholds their positions in the reheater dryer at the Belgium Power services as well. Our partnership with AcousticEye has proven to more than 20%. Several tubes Station. Source: GMA be a winning opportunity both were found to have severe pitting and holes were found within 30 they were cut and analyzed in an inde- for us and our customers.” centimeters of the inlet. Other tubes pendent laboratory. All the data found with the AcousticEye Dolphin was AcousticEye USA exhibited varying degrees of blockages. After receiving the report, 10 tubes found to be consistent with the labora- (713) 861-3270 were pulled for physical validation; tory findings. The customer was highly www.acousticeye.com

ATS calibration blocks... a step (block) above the rest. Custom requests are welcome Standard Specifications Metric & English Versions Carrying Case Available Sets Available

www.ndtmag.com

NDT SPECIAL SECTION QLT04071ATSNDT.indd 1

APRIL 2011 ● 25 NDT 3/7/07 9:44:26 AM

Microspectrophotometer The 20/20 PV microspectrophotometer automatically measures spectra by absorbance, reflectance, fluorescence and emission from the deep ultraviolet to the near infrared of submicron-sized sample features. It was designed to be programmable with touch-screen con-

LED Task Lights

NDT Inspection System

DynaLume LEDLite illuminators are designed to produce electronically adjustable levels of brilliant white light for visual

The ONT-365 On-Trak nondestructive testing (NDT) inspection system is an overhead track light-style modular system that has ultraviolet and white light LEDs attached to a mountable platform. It is designed for use in NDT inspection booths, and for pre-inspections and

inspection tasks. The computer-designed, integral paralliptic reflectors and universal beam pattern provide high usable light levels. The reflectors’ average life at the highest intensity is 50,000 hours.

Scientific Instruments (847) 679-1242 www.scientificinstruments.com trols so that it can automatically analyze microscopic samples with ultravioletvisible-near infrared (NIR) spectroscopy and microscopy. Applications include contamination analysis of hard disk components, thin film measurement of semiconductors, microcolorimetry of flat panel displays and quality control of pharmaceuticals.

Multi-Channel Flaw Detector

Craic Technologies Inc.

Siui

(310) 573-8180 www.microspectra.com

86-754-88250150 www.siui.com/ndt

The CTS-602 is a multi-channel flaw detector using phased array imaging technology. Its sector and linear scan is designed to meet nondestructive testing (NDT) inspection demands. It can be used in aerospace and transportation. It has up to 32 T/R channels, compatible with 16/32/64/128-element probes.

screening applications requiring maximum uniformity of coverage over a large area. It has four broad-beam lamp heads, which allows inspectors to move the lamp heads anywhere along the tracks so that beam patterns can be made to fit specific needs.

Spectronics Corp. (800) 274-8888 www.spectroline.com

Materials Testing Machine The LS1 single-column materials testing machine performs low-force measurements for materials testing applications under 1 newton of force. Linear guide technology, preloaded ball screws and software compensation systems perform

Ultrasonic Flaw Detector The Epoch 600 digital ultrasonic flaw detector is a portable instrument with conventional flaw detection capabilities. It weighs 3.72 pounds; has a video graphics array sunlight viewable display, a tunable square wave pulser, and was designed to comply with 12668-1. It has a digital high dynamic range receiver and digital filtering.

Olympus (781) 419-3905 www.olympus-ims.com 26 NDT ● APRIL 2011

NDT SPECIAL SECTION

www.ndtmag.com

high-precision displacement measurement. Industry applications include plastics, packaging, medical devices, automotive, electronics, textiles, rubber and pharmaceuticals. It can be used for tensile and compression testing, friction, tearing, peeling, insertion or extraction and creep or relaxation.

Lloyd Instruments (727) 536-6000

www.lloyd-instruments.com Shearography System The mobile ISISmobile shearography system has an integrated robot interface for an automatic test procedure. Operators receive a spatially accurate image of the part surfaces they have tested and can assign each measurement result to the surface data. This guarantees the full documentation of the test; operators can concentrate on the testing on hand and leave the traceability to the robot system and the software. The ISISmobile 3010 and ISISmobile 3100 mobile shearography systems enable testing of various composite components for nondestructive material testing.

Steinbichler Optotechnik GmbH +49-8035-8704-0 www.steinbichler.de

Portable Flaw Detector The USM Go is a portable flaw detector for use in the aerospace and automotive industries. It weighs 2.2 pounds and is designed for ease of prolonged operation in the harshest inspection environments. It has pressure-responsive, joystick con-

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Mass Spectrometer The Citius LC-HRT is a mass spectrometer for the liquid chromatography-mass spectrometry (LCMS) market. It uses Leco’s folded flight path technology to provide mass spectra at more than 100 spectra per second, and resolutions of up to 100,000. The system uses electrospray ionization (ESI) and atmospheric pressure chemical ionization (APCI) and desorption electrospray ionization (DESI) sources.

Leco Corp. (269) 985-5496 www.leco.com trol, ergonomic design and features data display resolution on an 800 by 480 pixel screen. The USM Go is dust- and waterproof to IP67 certification standards and proven to withstand shock and vibration.

GE Inspection Technologies (866) 243-2638 www.geinspectiontechnologies.com

Ultrasonic Flaw Detector The ultrasonic flaw detector rectifies in four ways: positive half-wave, negative half-wave, full wave and radio frequency. It has two scanning modes; gate alarming function; 32 detecting channels available with a separate detecting parameter and DAC curve in every channel. It has three detecting modes: single-probe, dualprobe and transmission.

Time +86 10 6298 5476 www.time-ndt.com

Ultrasound Camera The i600 Acoustocam provides ultrasound imaging and is a portable, handheld system for pulse-echo inspections. It has multiangle shear-wave support with throughtransmission applications. This system is configured in a variety of packages from water tanks to automated systems packaged by third party systems integrators

Imperium (301) 431-2900 www.imperiuminc.com

NDT BUSINESS CARDS These easy-to-use cards are a handy and low-cost way to reach NDT and material test buyers.

Sunny Coverly P: 610.932.8350 • F: 248.283.6587 [email protected]

NDT SPECIAL SECTION

APRIL 2011 ● 27 NDT

Hardness testing the handy way!

Equotip Piccolo from Proceq SA provides a new fully-integrated portable testing solution for metals:

The one-hand EQUOTIP hardness tester! It’s innovative charge-release mechanism enhances usability and speeds up measurements. Proceq‘s Piccolo offers: sSTANDARDIZEDMEASUREMENTS$).!34-! sTOPTESTINGACCURACYBEYONDTHESTANDARDS sAUTOMATICCORRECTIONFORTHEIMPACTDIRECTION sCONVERTSTOALLCOMMONHARDNESSSCALES sSTATISTICSAVERAGE STANDARDDEVIATION MINMAX RANGE sBIDIRECTIONALCOMMUNICATIONVIA53"AND0)##/,).+SOFTWARE

NDT BUSINESS CARDS - These easy-to-use cards are a handy and low-cost way to reach NDT and materials test buyers. Sold on a 7-time basis, include your Business Card Ad in every issue of NDT! Your ad will gain the attention of an active NDT buying audience. Promote your training, consulting, calibration or professional service. To place your NDT Business Card Ad, please contact:

Proceq USA, Inc. #ORPORATION$RIVE !LIQUIPPA 0! 4EL    &AX    [email protected]

N

EW

Sunny Coverly Inside Sales Manager P: 610.932.8350 F: 248.283.6587 7 [email protected]

www.proceq-usa.com

Advertiser

Page

Phone

Applied Test Systems Inc. ASNT Bruker Elemental Carestream Health Curtis Industries Inc. Gradient Lens Corp. Instrument Technology Inc. NDT Systems Olympus NDT Proceq USA Inc. Scienscope Spectronics Corp. Test Equipment Distributor Thermo Niton Analyzers LLC Verimation Technology Yxlon International

25NDT 22NDT 7NDT 1NDT 25NDT 21NDT 11NDT 12NDT IFCNDT 28NDT 17NDT 3NDT 16NDT 13NDT 27NDT BCNDT

(724) 283-1212 (800) 222-2768 (800) 366-9956 (724) 545-8333 (800) 536-0790 (413) 362-3606 (714) 893-2438 (800) 225-8330 (724) 512-0330 (800) 216-1800 (800) 274-8888 (800) 962-1788 (978) 670-7460 (800) 521-5245 (330) 798-4834

Web Address www.atspa.com www.asnt.org www.handheldxrf.com www.ndt.carestream.com www.curtis-test.com www.gradientlens.com www.scopes.com/v5 www.ndtsystems.com www.olympus-ims.com www.proceq-usa.com www.scienscope.com www.spectroline.com www.tedndt.com www.thermoscientific.com www.verimation.com www.yxlon.com

This index is provided as a reader service. The publisher assumes no liability for errors or omissions. 28 NDT ● APRIL 2011

NDT SPECIAL SECTION

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