Quality July 2011

N JO G R IN M e in M TH K OU a E E g D P IN A a .C T z O y lit u a LI Q JULY 2011, VOLUME 50/NUMBER 7 WWW...

Author: Gillian Campbell

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JULY 2011, VOLUME 50/NUMBER 7 WWW.QUALITYMAG.COM

TABLE OF

CONTENTS QUALITY MAGAZINE

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JULY 2011

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VOLUME 50

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NUMBER 7

DEPARTMENTS 6

FROM THE EDITOR

Comparing Salaries 8

INDUSTRY NEWS

Positive Global Outlook for Industrial Manufacturing M&A Relationships Improve Among Automakers, Suppliers GE Opens Sustainable Source: Creaform

Manufacturing Center 18 FACE OF QUALITY

Enhance Your Quality Culture

20 FEATURES

19 OTHER DIMENSIONS

Training?

50 YEARS OF QUALITY

22 HANDHELD GAGES: THE INDUSTRY’S WORKHORSE Every shop has a variety of handheld gages hanging around. You may use them every day and not even give them a second thought. This month Quality takes a look back at the industry’s workhorse.

28 CERTIFICATION/REGISTRATION GUIDE Companies provide information on the standards in which they specialize.

30 SERVICES GUIDE Companies provide information on the specific calibration, management and measurement/test/inspection and services they offer.

42 SOFTWARE SELECTION GUIDE The Software Selection Guide highlights products from various companies that distribute to test, inspection and measurement markets. Products ranging from CMM programming and simulation to ISO software are highlighted.

20 QUALITY 101

Back to Basics with 3-D Optical Measurement 62 CASE STUDIES

Quality Measurement for the Automotive Market Scanning to Fit 66 QUALITY PRODUCTS 70 CLASSIFIEDS 72 ADVERTISING INDEX

NEXT MONTH

QUALITY MANAGEMENT

52 MONEY MAKES A COMEBACK Quality professionals are seeing more money line their pockets.

Inline Gaging Surface Measurement Document Control Supply Chain Quality

JULY 2011, VOLUME 50/NUMBER 7 WWW.QUALITYMAG.COM

ABOUT THE COVER

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It’s been a bumpy road the past few years, but now that the economy has leveled out somewhat, the quality professional is receiving his proverbial piece of the pie. Source: Zygo Corp.

QUALITY | July 2011

www.qualitymag.com

Y OU R

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ON BENCHTOP VISION SYSTEMS

Galileo EZ Manual Vision Systems are compact, benchtop devices that are easy to learn and use, powerful and precise. They are available with innovative new M3 Control – a compact touchscreen interface. X-Y-Z MEASURING RANGE

EZ200: 8” x 4” x 6” (200 x 100 x 150mm) EZ300: 12” x 6” x 5.5” (300 x 150 x 125mm) New X & Y axis quick release levers for fast axis positioning Zoom Optics: 6.5:1

M3 CONTROL

Touchscreen-based graphic interface (shown with optional keyboard) Pan and zoom with a pinch, swipe or touch Works with active part views and live video feeds Video touch probe; touch and click to capture feature edge points Instant feature determination and measurement with a single touch Annotate one or several features simultaneously Windows 7 based

To gain your advantage with Starrett Innovation, visit http://featured.starrett.com/vision-M3

QUALITYMAG.COM

ONLINE TOC VISIT WWW.QUALITYMAG.COM FOR DIGITAL EDITIONS AND WEB EXCLUSIVE CONTENT

Available On-Demand CAM Analytics Manufacturing Processes Quality In the case of parts produced on well-maintained CNC equipment, nearly all problems that result in deviation from speciﬁcation can be eliminated at the front end of the manufacturing process using powerful analytical tools available in the CAM software. This is essential in many industries where short runs mean that a single defective part could prevent a project from being proﬁtable. Quality Software & Analysis: Is Your Process Performing? One 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 client-base, which extends globally across tens of thousands of clients in all types of industries. Readers Respond: Is Quality Deﬁned in Terms of the Customer? In the ﬁrst of Qualitymag.com’s Reader’s Respond series, quality professionals tackle the debate about who really dictates quality. Visit www.qualitymag.com to weigh in with your opinions today.

Industry experts share their views on the latest in quality and manufacturing: • Jim’s Gems: Weekly Updates! • NEW! Shifting the Paradigm

Eddy Current Testing: Its Many Beneﬁts and Applications Measurement 101: Essential Knowledge August 9, 2:00 p.m. ET CAD-Based Inspection Using Contact Measurement

CONNECT WITH QUALITY: Connect with us to receive updates and to network with other industry professionals just like you.

• 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

Three-Part Interview with Quality Professional of the Year

Take a look inside Jay Leno’s Garage Jay uses a Faro 3-D scanner to duplicate a part to restore a 1922 engine.

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

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QUALITY | July 2011

Paul Jr. Designs Paul Jr. Designs looks for the latest technology to advance the level of customization it can provide to its customers.

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Precision is Our Business.

FROM THE EDITOR

COMPARING SALARIES A FAIR DAY’S WORK FOR A FAIR DAY’S PAY.

A GILLIAN CAMPBELL

nnual salaries for quality professionals are on the rise…finally. In Quality’s 11th Annual State of the Profession Study, respondents indicated that salaries average $78,505 this year, a 6% increase from last year’s average annual salary of $74,028. Still, that $78,505 isn’t quite enough to cover the $110,000 that Dallas Mavericks’ owner Mark Cuban reportedly paid during his team’s post-finals celebration—$90,000 for a bottle of Ace of Spades champagne, plus a $20,000 tip. Nor is the average quality professionals’ salary anywhere near that of NBA finals MVP Dirk Nowitzki’s $17.3 million, 2011 NBA MVP Derrick Rose’s $5.5 million or Stanley Cup Finals MVP Tim Thomas’ $6 million. And these figures don’t even take into account the millions they make every year from endorsements. As the NFL lockout drags on, Commissioner Roger Goodell and Jeff Pash, the NFL’s lead labor negotiator, have had their salaries reduced to $1 each while the league’s labor impasse is unresolved. Even with their $1 salaries, I doubt they’re having a hard time making ends meet. Dream as we might, most of us will never take home anywhere near an athlete’s salary. According to the Bureau of Labor Statistics, the average annual salary in the United States is $44,410, so while quality professionals take home much less than professional athletes, they still take home 43.4% more than the average worker. Let’s take a look at the annual salaries from a variety of other industries, as reported by the Bureau of Labor Statistics Web site: • Dentists, $158,770 • Lawyers $129,440 • Air traffic controllers, $110,280

• Nuclear engineers, $101,500 • Police officers, $55,620 • Elementary school teachers (excluding special education), $54,330 • Firefighters, $47,730 • Painters, $26,680 • Childcare workers, $21,110 • Fast food cooks, $18,540 Of course, many people don’t go into a particular career because of the money. They do it because they enjoy the work, want to make a difference in their own way, or they simply have to pay the rent or mortgage. When I visited the Daimler Trucks North America Cleveland Truck Manufacturing Plant in Cleveland, NC, earlier this year, I spoke with UAW representative Chris Smith. He mentioned that, in part, their contract labor agreement is about doing a fair day’s work for a fair day’s pay. When it comes right down to it, isn’t that all we really want—to be paid fairly for the work we undertake each and every day? Do you feel you are fairly compensated for the work that you do? Share your thoughts with me at [email protected], or with other members of the Quality community at the Quality Magazine LinkedIn Group page, the Quality Facebook page and on Twitter at http://twitter.com/QualityMagazine.

Gillian Campbell, Editor [email protected]

Editorial ofﬁces: 155 N. Pﬁngsten Rd., Suite 205, Deerﬁeld, IL 60015 (248) 362-3700 • fax (847) 405-4100 • www.qualitymag.com

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QUALITY | July 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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COMING EVENTS SEPTEMBER 13-15 MATERIALS TESTING 2011 Telford, United Kingdom British Institute of Non-Destructive Testing www.materialstesting.org 20-22 QUALITY EXPO, Chicago, UBM Canon, (310) 445-4200 www.canontradeshows.com/expo/qexpo11

BUSINESS NEWS | COMING EVENTS | PEOPLE NEWS | MERGERS

OCTOBER

POSITIVE OUTLOOK FOR GLOBAL INDUSTRIAL MANUFACTURING M&A

5-6 2011 NORTHEAST SHINGO PRIZE CONFERENCE, Springfield, MA, The Greater Boston Manufacturing Partnership (617) 287-7630, www.neshingoprize.org 16-20 MATERIALS SCIENCE & TECHNOLOGY 2011 Columbus, OH, ACerS, (614) 794-5894 www.matscitech.org 24-28 ASNT FALL CONFERENCE AND QUALITY TESTING SHOW, Palm Springs, CA The American Society for Nondestructive Testing, (800) 222-2768 www.asnt.org/events/calevents/ calevents.htm

PEOPLE NEWS Lecky Integration (Little Falls, NY), a technical consultant company that partners with government agencies, system integrators, OEMs, Fortune 500 companies and entrepreneurial start-ups, has doubled in size since the start of the new year. Recent hires include: • JOSH JOHNSON, a graduate of William and Mary with a degree in computer science and a graduate of Full Sail University, who also holds a bachelor’s degree in Game Development. • DUSTIN HOLTZ, a graduate of Full Sail University, with a bachelor’s degree in Game Development. DON MANFREDI has joined Coherix (Ann Arbor, MI) as vice president of the firm’s automotive operations in the Americas. Coherix is a pioneer in the development of 3-D machinevision technology to detect manufacturing defects in powertrain and other precision automotive components. Renishaw plc’s (Gloucestershire, UK) Chairman and Chief Executive SIR DAVID MCMURTRY has been elected as a fellow of the Royal Society, the United Kingdom’s national academy of science. McMurtry will join a fellowship of the most eminent scientists, engineers and technologists from the United Kingdom and the Commonwealth, all of whom are elected for life through a rigorous peer review process on the basis of excellence in science.

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QUALITY | July 2011

NEW YORK, NY—A significant increase in merger and acquisition (M&A) volume and value in the first quarter of 2011 signals a positive outlook for global industrial manufacturing deal activity, according to Assembling Value, a quarterly analysis of M&A activity in the global industrial manufacturing industry by PwC US. While smaller deals and deals with undisclosed values remained the drivers of activity, the number of mega, large and middle market deals in the first quarter of 2011 are on track to exceed 2010 levels, according to PwC. In the first quarter of 2011, there were 36 deals worth more than $50 million amounting to $16.6 billion, compared to 14 deals totaling $2.3 billion in the first quarter of 2010, an increase of 157% in volume and 622% in value. According to PwC, a recovery of mega deal activity in the first quarter of 2011 also helped contribute to the rise in average deal value to $500 million from $200 million in the first quarter of 2010. There were four transactions with value of at least $1 billion in the first quarter of 2011, which represented approximately 67% of total deal value, or $11.2 billion, compared with no mega deals in the first quarter of last year and 10 in all of 2010. “Increasing confidence in the continuing global economic recovery combined with stronger balance sheets, improved financial markets and greater credit availability should create favorable conditions for deals and further stimulate industrial manufacturing M&A activity in the coming months,” says Barry Misthal, U.S. industrial manufacturing leader for PwC. “We expect to see ongoing global infrastructure

spending and an increase in mega deal activity if the global economy continues to recover, capital becomes more accessible and emerging and developing markets experience significant growth.” Consistent with levels set in recent quarters, strategic investors led first quarter deal activity with 72% of deal volume for transactions worth more than $50 million, while financial investors contributed approximately 28%. According to PwC, financial investors have become increasingly active in mega deals—contributing half of first quarter 2011 mega deal activity with $6.3 billion—signaling their strong comeback to the M&A scene. Non-U.S. affiliated deals continued to dominate M&A activity as companies looked to gain a presence in emerging and developing markets with higher growth potential. During the first quarter of 2011, deals excluding U.S. targets and/or buyers represented 69% of deal value with 24 deals worth more than $50 million, amounting to $11.5 billion. The majority of deals in the first quarter of 2011 came from the U.K. and Eurozone, and Asia and Oceania regions. Thirty-nine percent of targets and 28% of acquirers were in the UK and Eurozone region while 36% of both targets and acquirers were in Asia and Oceania. “Due to a more favorable regulatory environment and advanced capital markets, U.K. and Eurozone targets are likely to be a major catalyst of deal activity, while the Asia and Oceania region also continues to be attractive for its high economic growth and lower production costs,” adds Misthal. “After a strong increase in 2010, North America has significantly decreased its contribution to deal volume, partly because of slower economic recovery and less attractive market conditions.”

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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Globalization has become a major driver for cross-border M&A activity due to increased deregulation, privatization and corporate restructuring, according to PwC. In the first quarter of 2011, cross-border deals represented 50% of total deals valued at more than $50 million with 18 transactions, driven by companies seeking to gain market share in new, more attractive markets. “As the global economy continues to recover, we expect that companies will seek to gain competitive advantage by broadening their international presence and may engage in cross-border transactions to follow customers or gain new ones,” continues Misthal. “With M&A activity increasing across the globe, executives are facing talent management challenges, including organizational design, integration planning and the cultural blend between acquirer and target. Companies should consider having a disciplined approach to employee integration, which will help them achieve desired synergies, build momentum and instill confidence among stakeholders.” The industrial machinery category realized the largest increase in deal volume and represented the primary driver of activity during the first quarter of 2011, accounting for 56% of total deals worth more than $50 million, including two of the four mega deals in the first quarter. The two remaining mega deals of the first quarter of 2011 came from the electronic and electrical equipment sectors. Rubber and plastic products also increased in volume, accounting for 19% of deal activity, compared to 14% of deals in all of 2010. For a copy of Assembling Value, PwC’s quarterly analysis of M&A activity in the global industrial manufacturing sector, visit www.pwc.com/us/ industrialproducts.

WORKING RELATIONS IMPROVING AMONG DOMESTIC AUTOMAKERS AND SUPPLIERS DETROIT—According to the 11th annual study of working relations between the six North American automakers and their suppliers, the U.S. Big Three automakers: Ford, Chrysler and General Motors—continue to show steady improvement, and the Big Three Japanese automakers: Honda, Toyota and Nissan—continue to slip.

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NEWS ASSOCIATION NEWS

easy • accurate • automatic

Break Edge and Radius Inspection

Dual-Stripe Handheld USB Sensor

Twenty-nine engineers and scientists from industry and academia now have the prestigious SAE INTERNATIONAL (SAE, Warrendale, PA) status of SAE Fellow. SAE Fellowship status is the highest grade of membership bestowed by SAE International. It recognizes outstanding engineering and scientific accomplishments by an individual that have resulted in meaningful advances in automotive, aerospace and commercial-vehicle technology. The program, established in 1975, recognizes an average of 20 worldwide recipients for this honor each year. The 2011 recipients, listed in alphabetical order, include: • Dr. Ewa A. Bardasz, technical fellow, Lubrizol Corp. • Dr. Bryan L. Dodson, executive engineer, Continuous Improvement/ Six Sigma, SKF, USA

• Designed for limited access areas • Operator feedback for optimum positioning • Algorithm corrects for pitch and yaw misalignment • High resolution scan, accuracy to within ± 0.0005-inch • USB connection to laptop, tablet or to LaserGauge LG1200 controller

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• Michael C. Dudzik, vice president, Science & Technology, Washington Operations/Corporate, Lockheed Martin Corp. • Dr. Wayne A. Eckerle, vice president, Research & Technology, Cummins Inc. • Horacio Aragonez Forjaz, executive vice president, Corporate Affairs, Embraer (Empresa Brasileira de Aeronautica S.A.) • Dr. Jaal B. Ghandhi, Grainger professor of Sustainable Engineering, Mechanical Engineering, University of Wisconsin-Madison • Dr. Mircea Gradu, director, Transmission and Driveline Engineering, Head of Virtual Analysis, Chrysler Group LLC • Greg W. Henderson, director, Product Lifecycle Management, retired, Lockheed Martin Aeronautics Co. • Keith Jackson, chief technology officer, Electrical Power and Control Systems, Rolls-Royce PLC • Dr. Linos J. Jacovides, director, retired, Delphi Research Labs Badih A. Jawad, Ph.D., professor and chairman, A. Leon Department of Mechanical Engineering, Lawrence Technological University

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QUALITY | July 2011

• Richard E. Kleine, vice president of Quality and Business Enterprise, Mid Range Engine Business, Cummins Inc., and the 2011 president of SAE International

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NEWS • Dr. Ming-Chia Daniel Lai, professor, Mechanical Engineering, Wayne State University • Patrick Leteinturier, senior principal, Automotive Systems, Infineon Technologies AG • Paul A. Machiele, center director, Assessment and Standards Division, U.S. Environmental Protection Agency (EPA) • Dr. Jeffrey D. Naber, director, Advanced Power Systems Research Center and Associate Professor, Department of Mechanical Engineering-Engineering Mechanics, Michigan Technological University

ASSOCIATION NEWS

• Marc Parent, president and chief executive officer, CAE Inc. • Dr. Charles E. Roberts, Jr., Institute Engineer, Engines, Emissions and Vehicle Research Division, Southwest Research Institute • Gary W. Rogers, PE, president and CEO, FEV Inc. • Dr. Pradeep K. Rohatgi, distinguished professor and director, Composites and Advanced Materials Manufacture Centers and Tribology Laboratories, University of Wisconsin-Milwaukee • Dr. Prakash T. Sathe, senior vice president, Engineering & Business Development, Rapid Global Business Solutions Inc. (RGBSI)

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2011 Training Courses Courses, dates & locations: www.dnvtraining.com or call for a catalog 1-800-486-4524

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QUALITY | July 2011

CONTINUED

The 2011 North American OEM Tier One Supplier Working Relations Study, conducted annually by Planning Perspectives (Birmingham, MI), tracks supplier perceptions of working relations with automaker customers in which OEMs are ranked across the six major purchasing groups broken down into 14 commodity areas. The results of the study are used to calculate the Working Relations Index (WRI) based on 17 working relations variables. This year, 451 suppliers participated, representing 63% of the six automakers’ annual buy. Ford continues to lead the U.S. automakers in having the best relations with its suppliers staying in third place overall, while GM and Chrysler continue to improve. Chrysler, while remaining in last place, has had its second straight year of significant improvement. Among the Japanese automakers, Honda, which was in first place overall for the past two years, has continued to drop and has slipped to second place behind Toyota, which appears to have bottomed out, while Nissan remains stuck in neutral in fourth place. Comparing the six U.S. and Japanese automakers overall, Toyota is in first place, followed by Honda, Ford, Nissan, GM and Chrysler. This year, 540 sales persons from 415 Tier 1 suppliers—representing 1,984 buying situations and 63% of the OEMs’ annual buy—responded to the survey. Demographically, the supplierrespondents represent 37 of the Top 50 North American suppliers, 63 of the Top 100 and 80 of the Top 150 North American suppliers. The study culminates in the Working Relations Index (WRI) which is a quantitative ranking by suppliers of their working relations with each of the six OEMs.

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• Victor E. Saucedo, senior manager (retired), F-117 Program, Lockheed Martin Aeronautics Co.

• Dr. Patrick B. Usoro, technical fellow, Vehicle Development Research Lab, General Motors Research & Development

• Dr. Myoungho Sunwoo, professor, Automotive Engineering, Hanyang University

• Dr. Bryan D. Willson, professor of Mechanical Engineering and director of the Engines & Energy Conversion Laboratory, Colorado State University

• Dr. Galina M. Susova, head, Quality Management System Department, National Institute of the Aviation Technologies • Dr. Tau Tyan, Safety CAE Engineer, Safety Methods Development, Ford Motor Co.

• Dr. Jianwen James Yi, technical leader, Powertrain Research and Advanced Engineering, Ford Motor Co. • Dr. Jianwei Zhang, vice president, China Automotive Technology and Research Center (CATRC)

PRATT & WHITNEY AWARDED $1.13B CONTRACT FOR F135 ENGINE PRODUCTION EAST HARTFORD, CT—The U.S. Department of Defense has awarded Pratt & Whitney a $1.13 billion contract for F135 production engines to power the F-35 Lightning II. Pratt & Whitney and the DoD have reached an agreement on price and terms for the LRIP 4 contract, originally awarded in July 2010, which contains fixed-price and cost-plus incentive fee elements. This low rate initial production (LRIP) contract includes production, spare parts, sustainment and delivery of the fourth lot of F135 engines. Pratt & Whitney is a United Technologies Corp. company. “This contract provides our customer with a 15% savings on the conventional takeoff and landing/ carrier variant, compared to LRIP 3, and demonstrates our commitment toward meeting aggressive cost reduction goals for the F135 engine,” says Bennett Croswell, president of Military Engines, Pratt & Whitney. “It also speaks to the maturity of our engine, which builds on the proven technology of our F119 engine. The F135 engine has powered all 868 F-35 flights, including 100 vertical landings in the short takeoff/vertical-landing (STOVL) configuration.” The fourth lot of F135 engines includes 18 conventional take-off and landing (CTOL) and 19 STOVL engines. Deliveries for this lot are slated to begin in the fourth quarter of 2011. The engines delivered in LRIP 4 will support the U.S. Services, the United Kingdom and the Netherlands. Pratt & Whitney has designed, developed and tested the F135 to deliver the most advanced fifth-generation fighter engine for the United States and its allies around the world.

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BALL GAGE INSTEAD OF A CYLINDRICAL PLUG GAGE. Save time with the self centering spherical surface of the ball gage. When measuring a large number of holes it can be 100 times faster. Put one or two ﬂats on the ball and ﬁnd any out-of-round holes. Measure how parallel the space is between two surfaces and or the size. You can get into inside diameters or inside spherical surfaces of rod end bearings.

NEWS AMERICAN SOCIETY FOR QUALITY (ASQ, Milwaukee, WI) announced the following slate of officers for the 2012 term, which includes newly created titles as part of ASQ’s governance improvements plan: • Past Chair–E. David Spong, Boeing Co. (retired), Rancho Palos Verdes, CA • Chair–James J. Rooney, ABSG Consulting, Knoxville, TN • Chair-Elect–John Timmerman, Marriott International Inc., Sterling, VA • Treasurer–William B. (Bo) McBee, HewlettPackard Co., Houston, TX; • Newly Elected Board Member–Joanne D. Mayo, Nortel, Cary, NC and • Newly Elected Board Member–Kathleen Goonan, Mongan Institute for Health Policy, Boylston, MA.

GE OPENS SUSTAINABLE MANUFACTURING CENTER IN SAUDI ARABIA DAMMAM, SAUDI ARABIA—GE celebrated the grand opening of the GE Energy Manufacturing Technology Center.

ASSOCIATION NEWS

CONTINUED

The model works to define the responsibility, accountability and authority of the executive director, the president, the chairman, the office of the president, the board and the office of the president structure, job titles and job descriptions. The ASQ membership approved changes to the current body of governance. Effective immediately, the new titles are: • The office of the president becomes the executive council. • The president-elect becomes chair-elect. • The president becomes chair. • When the president fulfills his term, he then becomes past chair. • Executive director becomes chief executive officer.

The 32,000 square-foot center in Dammam, Saudi Arabia, includes a manufacturing facility for high technology equipment for the power, water and oil and gas industries; a service and repair center for advanced

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• Highly portable and economically priced - traceable surface roughness measurements • Solidly built for confident, reliable surface finish gaging on the shop floor or in the laboratory • Switchable for Ra, Rmax/Ry or Rz with selectable cutoff lengths • Four position probe - which operates in any orientation, provides unmatched versatility for your application needs • Get the original Pocket Surf® - made in the USA • Available for fast delivery Pocket Surf® is a registered trademark of Mahr Federal Inc. Product configuration is a trademark of Mahr Federal Inc.

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

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NEWS

BUSINESS NEWS

PRODUCTIVITY QUALITY INC. (Plymouth, MN) and GDO PRECISION TECHNOLOGY (Eygelshoven, Netherlands) have signed an agreement that names PQI as importer and exclusive North American distributor of GDO’s Nuremberg Stent Inspection-7 system. The NSI-7 system is the result of three years of research and development in close collaboration with stent manufacturers. NSF INTERNATIONAL STRATEGIC REGISTRATIONS LTD. (Ann Arbor, MI), a management systems registration company, has acquired accredited registration company AQA INTERNATIONAL LLC (Columbia, SC) and AQA’s current international operations. As a result, NSF-ISR and AQA-certified companies will benefit from a wider global footprint in China, Korea, India, Turkey and Malaysia; a larger North American presence and a broader array of service offerings. LABSPHERE INC. (North Sutton, NH) has been named company of the year by its parent company, UK-based Halma p.l.c. The annual award recognizes the company with the best all-around performance of the 40 Halma group companies worldwide. While one of the criteria is significant growth in sales and profits, the award also takes into account good governance and overall management of engineering and manufacturing. Metrology equipment supplier NANOMETRICS (Milpitas, CA) opened a Singapore advanced metrology center to support its customer base in Asia. The center should give dedicated support throughout Asia for customers requiring advanced modeling of complex structures and recipe development. It also will act as a training center for regional customers and Nanometrics’ branch offices.

turbine equipment; and a training center to empower Saudi college students. As part of the launch, GE announced an additional $150 million investment in the project, bringing the company’s total commitment to $250 million. The end-to-end goal of the center is key. GE can repair advanced technology gas turbine-related parts locally,

DOUGLAS DYNAMICS INC. (Milwaukee, WI), a designer, manufacturer and seller of snow and ice control equipment for light trucks, announced it was recently ranked No. 3 on MILWAUKEE JOURNAL SENTINEL’S Top 100 Workplaces List in the Top Mid-Size Workplace category. This is Douglas’ second consecutive year on the list, an annual ranking of the top 100 workplaces in Southeastern Wisconsin based on input from employees and workplace attributes. In 2010, Douglas Dynamics was ranked No. 7 in the top mid-size workplace category. ACU-GAGE SYSTEMS (Hudson, NH), a manufacturer of one, two-and three-axis noncontact video and laser measuring machines, has been awarded a contract from the U.S. Treasury Department’s Bureau of Engraving and Printing (BEP) for up to nine measuring systems. AcuGage Systems will supply three-axis measuring systems, which will be used to inspect the registration and alignment of all United States’ paper currency. The systems will be installed in Washington, DC, and in Fort Worth, TX. Global metal cutting and composites processing technology company MAG (Erlanger, KY) has acquired FOREST LINÉ INDUSTRIES GROUP (FLI, Paris, France). Forest Liné specializes in manufacturing systems for aerospace applications, dies/molds, large parts, titanium and composites processing. The company is a technology leader in composite wing and wing box applications, and operates sites in France, Germany, China and Canada, employing about 300. Jean Bertrand Prot will continue as president and CEO of FLI and join the MAG Executive board.

for instance, rather than send them out of the country, to save time and cost. The facility will create 2,000 new jobs, supporting goals outlined in Saudi Vision 2020, the Kingdom’s plan for economic development over the next decade. “As Saudi Arabia forges ahead with its ambitious development plans,” GE vice chairman John

Krenicki said at the opening, “the center underscores GE’s commitment to be closer to our customers who trust us to deliver the latest technologies and services across the energy landscape.” GE currently supports roughly half of the Kingdom’s electricity with more than 500 turbines installed throughout Saudi Arabia.

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NEWS VISTEON RECIEVES 2011 TOYOTA GLOBAL TECHNOLOGY AND DEVELOPMENT AWARD YOKOHAMA, JAPAN—Visteon Corp. received the Technology and Development Award from Toyota at its recent 2011 Suppliers Convention in Nagoya, Japan. The award recognizes noisereduction technology as applied to a low-cost fuel pump controller (FPC). Co-developed with Toyota, the technology is considered a breakthrough in the global automobile industry and is currently patent pending. The Technology & Development Award recognizes suppliers who have greatly contributed to boosting the product appeal of Toyota vehicles by developing world-leading new technologies and products. After strict evaluation, the prestigious award is presented to a select number of suppliers every year. “We are extremely pleased to be recognized by Toyota as a top innovator and technology leader,” says Donald J. Stebbins, Visteon chairman, CEO and president. “We continue to focus on partnering with our customers to create exceptional value.” FPC is an electronic module that controls the speed of the fuel pump according to the driving situation, to ultimately improve the fuel efficiency of the vehicle. By utilizing a proprietary printed wire board topology with a high-frequency direct current—direct current converter circuit, Visteon is able to significantly reduce the radiated electromagnetic noise of the FPC. This innovation also results in reduced weight, size and design complexity, and contributes to fuel economy through cost-effective application of the FPC for improved efficiency of the fuel pump system. The core technology can be applied to virtually all types of motor control systems, including those in electric/ hybrid vehicles. The high-quality FPC using this innovative noise reduction technology has been launched on Toyota’s multiple vehicle models in the Japan and U.S. markets.

regarding the U.S. economy, according to Grant Thornton LLP’s most recent Business Optimism Index, a quarterly survey of U.S. manufacturing business leaders. Only 40% believe the U.S. economy will improve in the next six months, down from 60% three months earlier. At the same time, 26% believe the U.S. economy will get worse, up from 3%.

“There are many factors causing concern amongst U.S. manufacturing leaders,” says Wally Gruenes, manufacturing practice leader at Grant Thornton LLP. “Soaring energy and raw material costs and Japanese manufacturing supply chain disruptions are weighing heavily, as are unresolved U.S. debt reduction issues and a corporate tax rate that still puts the U.S. at a global competitive disadvantage.”

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MANUFACTURING CONFIDENCE IN U.S. ECONOMY DROPS CHICAGO–U.S. manufacturing leaders have turned pessimistic

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July 2011 | QUALITY

17

FACE OF QUALITY

ENHANCE YOUR

QUALITY CULTURE WE NEED TO CHANGE THE WAY WE THINK ABOUT QUALITY. Editor’s note: This is part one of a two-part series on enhancing quality culture.

A

JIM

sked to give a short talk to a management class at a local university, I focused on a conversation that I had with Dr. A.V. Feigenbaum at the 2010 ASQ World Conference. We were engaged in a discusL. SMITH sion concerning the growth of quality and the major developments that were being influenced by the global economy. The following is a portion of that discussion and talk with the management class. Organizations and their leadership teams must embrace a different way of leveraging quality and think beyond terms of just preventing defects from getting into the hands of their customers. During the past few years, the environment is such that society demands that businesses deliver highquality value. Leveraging quality will feed all three consumers of an organization’s product—stockholders, employees and customers. Stockholders will be pleased Quality initiatives can no because margins will grow, financial ratios longer be contained to one will be positive and stock process will be department or function. enhanced. Employees will be motivated and engaged because of increased job security and an enhanced financial future. Customers will be happy because they will be getting high cost-price-value because of higher product quality. Quality initiatives can no longer be contained to one department or function. In order to move to the next phase, organizations have to adopt ongoing strategy to embrace quality as the fundamental, day-to-day DNA of its core values. Some of the major challenges influencing organizations include: accelerated changes in product development and manufacturing processes; customer demands for an increasingly higher standard of quality value—not just fewer defects—in the products and services they purchase; state-of-the-art technology in a range of business activities to speed time to market; and global distribution. As a result of these challenges, quality has become a global language for businesses and customers. Fun-

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QUALITY | July 2011

damental to any business’ competitive strength is how effectively it interprets and implements the language of quality, in terms of both technical and quality processes. At the core of this language is the realization that quality is what the customer, not the organization, says it is. This may seem fundamental because quality organizations have been saying this for some time; however, many organizational leaders don’t practice this concept in the board rooms or on the factory floor. Organizations must align all aspects of its operations— including marketing, design, manufacture, distribution and service—in very specific customer value terms. Processes must be focused, established, led and maintained to achieve customer value-based success. Many products, from cars to computers to cell phones, with low levels of defects or complaints in the traditional quality control sense, have experienced disappointing sales results. The reason for the disappointment is that the products do not provide the quality value customers are looking for in today’s markets. Quality needs to become a basis for guiding, empowering and supporting the constant pursuit of excellence by everyone in the organization. Most importantly, leadership has to recognize the basic principle that what makes quality better in one part of an organization, can make quality better in other parts of the organization. Quality has to become a cornerstone for constant management innovation and leadership, which is imperative for survival and growth. To meet the demands of the competitive environment and maintain their quality competitiveness, it is Feigenbaum’s belief that organizations must use their strength and leadership in order to remain economically healthy and f lourish in the future. To do so, organizations should focus on some key quality process areas, which we’ll look at in more detail next month. Coming next month: Five key strategies to enhance your quality culture. 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].

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OTHER DIMENSIONS

TRAINING?

WHEN IT COMES TO TRAINING, ENSURE STUDENTS UNDERSTAND THE BASICS.

E

very so often I receive a panicked request to provide training in dimensional metrology, or the name of someone who can do it when I’m not available. The urgency of the request is the first clue that someone is in damage control mode. Invariably such requests are the fallout from a quality audit—a finding that has to be fixed in 30 days or HILL COX so, if it can be. Another situation that leads to such requests involves corporate takeovers. A number of processes are applied that include integration, merging and resizing, which usually means expensive, skilled employees are put out to pasture in favor of unskilled, lower-cost newcomers. Panic requests for training usually note that it must be at the customer’s plant and not take more than a half day or so. Basically what is wanted at the end of it all is a warm body that can read an instrument and little Basically what is wanted more. Oh, don’t forat the end of it all is a warm get, each student will require a certificate. body that can read an It’s rather like training instrument and little more. a neurosurgeon in one easy lesson without getting complicated. Technical colleges offer basic training courses, but whether they can meet these requirements is a bit iffy. Still, if you are in such a situation, you should check them out. Discuss your needs with the instructor so everyone is singing from the same sheet music. If you intend to set up your own in-house training program, here are some considerations beyond how to read a micrometer: • Make sure the students can speak the language. By this I mean part feature talk: counterbore, through hole or bore, datums, center-line, blind bore, centerdistance, squareness, chamfer, run-out or TIR, keyway, slot, width, length, diameter, and inch and metric units of measure. • Ensure students understand some metrology basics. Examples would include, compare, accuracy, repeatability, linearity, master, standard(s), zero-setting, offsets, taper, roundness, range, capacity, tolerance, co-efficient of thermal expansion, measuring force, traceability, calibration, surface texture or finish, taper, ovality, parallelism, roundness, lobing, flatness and resolution to name a few.

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• If your company makes, buys or inspects threaded fasteners, elements of screw threads will have to be explained. Examples would include major, minor and pitch diameter, linear pitch, halfangle root, crest, classes of fit, thread wires and threads per inch. • Knowing how the instruments actually work is worthwhile so those using them have some idea where to look when things go off the rails. Simple explanations along with sources of errors when they are used can save a lot of problems in their use and help the instruments gain the respect they are entitled to. That would be my shopping list for folks checking component parts. I couldn’t cover it all in a day and I doubt anyone could absorb most of it, even if I could. Having “trained” your staff as noted above, one thing you’ll have to do is test them to see if they have acquired the skills necessary to take the measurements. The easiest way to do this is to give them items of known dimensions and see how closely their measurements match the known or calibrated values. You may want to use a couple of sample components for this purpose. They don’t have to be correct dimensionally since you are going through a comparative process. Rejected parts can be useful after all. Just keep them labeled so they don’t get mixed up with good parts. Some gages that have been rejected also can be used for such testing, but if they are badly tapered or out of round, you may have to mark the measurement locations so their geometry doesn’t mess things up. In some cases, you may want to use components with geometrical irregularities to see if your students find them. Needless to say, all of these activities should be recorded so an auditor can see that you have actually trained your people and the subjects and skills you taught them. Over the years I have taught classes in metrology and noticed that most people that are given the opportunity to learn more tend to want to do so. This attitude can be quite rewarding for the teacher, particularly when you see the pride when your charges master new skills and understand more about what their job entails. Hill Cox president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

July 2011 | QUALITY

19

QUALITY 101 With dynamic referencing, 3-D optical measurement technologies deliver increased accuracy. Source: Creaform

3-D optical measurement solutions sidestep these limitations by enabling automatic positioning and continuous device measurement: the self-positioning concept or dynamic referencing.

BACK TO BASICS WITH

3-D OPTICAL MEASUREMENT

Optical 3-D measuring devices’ shop-floor accuracy, decreased sensitivity to environment and higher measurement pace make them strong contenders to traditional quality control devices. BY DANIEL BROWN

I

t is a known fact: fixed coordinate measuring machines (CMMs) generate high accuracy measurements and can be automated, but they are expensive and offer no portability. In comparison, conventional articulated arms offer increased versatility and portability, but they are highly sensitive to environmental conditions; require a rigid setup; and are ill-adapted for shop-floor conditions. Simply put, the arm solutions eliminated CMM downsides, but also rid CMMs of two of their main advantages: stability of the machine and rigidity of the measurement setup. Optical 3-D measuring devices were developed in recent years mainly to compensate for these flaws, and they are bound to play an increasing role in the world of quality control and metrology. Their increased shop-floor

20

QUALITY | July 2011

accuracy, decreased sensitivity to environment and higher measurement pace make them strong contenders to traditional quality control devices. The success of 3-D measurement solutions that combine optics and sensors lies in the fact that they offer the benefit of optics—such as speed, portability, reduced sensitivity to the measurement environment and higher measurement volume—while remaining compatible with known, proven procedures. However, most of these optical measurement solutions still use mechanical technologies that present serious limitations in production environments. They require extreme stability throughout the measurement process, in addition to control templates and heavy bases which are costly, cumbersome and mostly inflexible.

HOW DO 3-D OPTICAL MEASUREMENT DEVICES WORK? The basic principle of this technology is that the optical CMM’s cameras track the position of the part and that of a 3-D scanner or touch probe simultaneously in a locked reference model, which makes measuring possible in all conditions. Factors such as instability in the machine or part setup, vibrations or thermal variations will have absolutely no effect on the output measurement accuracy. The core component of these systems is the dual camera sensor, which continuously measures the position of passive and wireless reflectors located in the measuring volume through optical triangulation. First, the sensor measures the position of targets, which have been previously fixed on a part or on a fixture. This way, the machine reference system is completely locked onto the part, which creates a stable alignment, even if the part, the fixture or the sensor is moved. In the same way, the sensor can measure the position of numerous targets placed on an optical CMM 3-D scanner and accurately locate the latter within the measurement volume. The localization is relative to the part itself, thanks to the targets placed on it. The same dual-camera sensor can be used with an arm-free portable CMM and work to localize the wireless probing apparatus. Therefore, the exact position of the tip sphere’s center also can be processed, and all the functionalities of a manual CMM become available to the operator without the requirement for stability. TECHNOLOGIES BEHIND AN OPTICAL CMM The first step is image processing. The challenge is to detect, with the highest accuracy possible, the 2-D position of each reflector.

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It is not an easy task to accurately localize small dots at a few meters distance to obtain a resolution of a few micrometers. Based on advanced mathematics and physics, highly sophisticated algorithms have been developed to provide 2-D localization of the reflectors with a resolution that can be a thousand times higher than the cameras’ basic resolution. Once all the 2-D coordinates from the images are processed, it is possible to compute the 3-D coordinates of each targets using the basics of photogrammetry. By using the 3-D coordinates of targets placed on the same object, it becomes possible to compute the position of this object, such as the probe, the scanner, a fixture or the part to be measured. 3-D MEASUREMENT FOR EVERYDAY APPLICATIONS Now, we have a 3-D optical CMM— and can proceed to 3-D measurement

Oil & Gas

Optical 3-D measuring devices are bound to play an increasing role in the world of quality control and metrology. Source: Creaform

as with any other type of CMM—but the difference is that we now have a better alternative for micrometerprecision 3-D measurements. With dynamic referencing, 3-D optical measurement technologies deliver increased accuracy, particularly in shop floor conditions. The

Automotive

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Daniel Brown is a product manager at Creaform (Lévis, Quebec). For more information, call (418) 833-4446, e-mail [email protected] or visit www.creaform3d.com.

Machining

Aerospace

Handheld Gages

Calibration Equipment and Services

Linear Measurement

Quality

www.gagemaker.com/quality

accuracy of an optical CMM is more than just a specification on a technical sheet. It will remain constant despite the quality of the setup, the environmental conditions or the operator’s level of experience. This technology is highly innovative, but also is based on extensive knowledge and proven technologies. This is a result of more than 20 years of research in image processing and optical triangulation fields and takes advantage of the photogrammetry, which has been commonly used in the aerospace industry for years. For these reasons, 3-D optical measurement technologies are bound to play an increasing role in the world of QC and metrology.

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July 2011 | QUALITY

21

50 YEARS OF QUALITY

Handheld Gages: The Industry’s Workhorse Every shop has a variety of handheld gages hanging around. You may use them every day and not even give them a second thought. This month Quality takes a look back at the industry’s workhorse. of the tool’s extreme tolerances. Dave DESIRE FOR ACCURACY DRIVES DiBiasio, national sales manager for DIGITAL TOOLS, MARCH 2002 Brown & Sharpe (North Kingstown, Electronic, digital handheld tools RI), says the jump from the analog have been around for more than three micrometer to the digital micrometer decades, but they were somewhat slow was a profound advancement to be accepted. Today, many w QUALITY because of the extremely small suppliers say that digital tool b Desire for Accuracy Drives Digital Tools measurements that the digisales are equal to or greater than m C nondigital tool sales. ttal version can take. “With a “Early on, they were still sstandard micrometer, there is QUALITY somewhat mistrusted by the a main barrel scale that breaks measuring and manufacturing tthe inch down to a 1∕10 inch, world,” says Steve Pike, group aanother scale on the barrel manager, precision measuring tthat breaks it down to thousandths, aand a vernier scale on the bartools, Mitutoyo America Corp. (Aurora, Aurora sandths rel that breaks it down to 10,000ths of IL). “The first ones were just okay. Not an inch,” he says. “Picture trying to use just Mitutoyo’s, but all manufacturers’ this in a standard shop environment, early versions. We struggled with trying which may not be well lit, and tryto make a tough, reliable and depending to look at one scale, then turn the able digital tool with a battery life that micrometer over and look at another was pretty good and a display that was one and go to a third to see which lines readable in low-light conditions,” he are lining up. All to try and determine says. “Now, we have built six or seven that reading. Without skill, there is a generations of digital calipers and it is huge potential for error.” our most popular tool.” The electronic nature of new The digital micrometer took a little micrometers has allowed manufacturlonger to catch on, probably because MEASUREMENT, TEST AND INSPECTION

Handheld measuring tools have withstood the test of time. By Larry Adams Senior Editor

TECH TIPS

䡲 Early manufacturers recognized the need to make it easier for workers to read measuring tools.

䡲 Today’s electronic handheld measuring tools, such as digital calipers and micrometers, offer ease of use, increased accuracy and long life. 䡲 Digital calipers are now appearing on the market that have been rated to protect the tool from an ingress of dust or water jets hitting the tool from any direction.

26

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QUALITY | July 2011

iceri Smith was a quality-driven man- new employees is quicker. ufacturer. He made wire mesh at his The same can be said of Chris Blanton, plant in Edinburgh, Scotland, and he quality manager for Accurate Bushing Co. wanted to improve quality by providing (Garwood, NJ), who uses handheld digital his workers with a micrometer that they tools. “These tools are used to take dimencould easily read. What he wanted was a sional measurements of high tolerance micrometer on which his workers could aerospace parts, which we fabricate,” he read the numbers and not have to count says. “Our dimensions call for very tight numbers and lines, but there wasn’t such tolerances, ranging up to 0.0001 inch in a micrometer on the market. So he invent- requirements, so digital is the only way to ed one. go. Digital tools, while certainly more Smith designed what is believed to expensive, tend to function better, give be the world’s first more accurate readings “digital” micrometer, and require somewhat and received a patent less training than do sometime between their analog counter1890 and 1893, accordparts. The old analog ing Dr. Victoria Beaustyle does not give us as champ, a Mitutoyoprecise a reading.” funded researcher for A slow start The Hawley Collection, Electronic, digital University of Sheffield handheld tools have (Sheffield, England). been around for more The device, which was than three decades, not electric as today’s but they were somedigital tools are, used a what slow in their mechanical display that showed inch mea- Ciceri Smith developed this “digital” acceptance. Today, many suppliers say surements three ways: caliper in the late 1800s so that his that digital tool sales 10ths, 100ths and employees could more easily and accurately read measurements. The are equal to or greater 1,000ths. It allowed micrometer has a digital display that his workers to quickly shows measurements in 1/10th inch, than nondigital tool sales. and accurately take 1/100th inch, 1/1000th inch. Photo: Copyright of Professor Francis Evans and the “Early on, they were measurements. Hawley Collection, University of Sheffield, still somewhat misCiceri Smith’s desire England, 2000. trusted by the measurto make a micrometer easier for his workers to use may be more ing and manufacturing world,” says Steve than a century old, but today’s quality Pike, group manager, precision measuring experts also have that desire. Experts such tools, Mitutoyo America Corp. (Aurora, as Wilson Silva, quality engineer at the IL). “The first ones were just okay. Not just automotive component manufacturer Mitutoyo’s, but all manufacturers’ early Dana Corp. (Toledo, OH), for instance. versions. We struggled with trying to Silva says that he uses digital tools because make a tough, reliable and dependable he found that the measurements that are digital tool with a battery life that was taken are more accurate and that training pretty good and a display that was read-

QUALITY / March 2002 www.qualitymag.com

ers to go beyond b d even these h miniscule i i l measurements. Today’s digital micrometers can read down to 50 millionths of an inch, DiBiasio says. Digital is not just confined to calipers and micrometers. A slew of handheld measuring tools such as ultrasonic thickness gages, hardness testers, surface analysis tools, height gages, torque wrenches, gap and flush transducers and others have all added electronic capabilities. Ease of use is a big reason; it is much easier to read a number than to count numbers on a vernier scale or lines on the barrel of a micrometer. The growing use of statistical process control (SPC) is another reason. In the past, results would be noted with paper and pencil, a time-consuming process that can lead to transposition errors, papers getting smudged by contaminants and, most importantly, out-of-tolerance conditions that are allowed to continue because some data analysis is not immediately accessible. Digital tools of all stripes usually are available with RS232 serial ports to connect via cable to a personal data assistant, portable data collector, or laptop or PC computer. This eliminates errors by cutting out the paper step, and also makes SPC analysis of measurement data available more quickly, sometimes in real time.

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QUALITY 101: CALIPER BASICS, AUGUST 2007 Calipers are extremely versatile tools for making a wide range of distance measurements, including both outside diameters (OD) and inside diameters (ID). While micrometers are more accurate, they have a limited measurement range, typically several inches. Calipers can span from 2 inches to 4 feet, depending on the length of the scale. External measurements are made by closing the jaws over the piece to be measured, while internal measurements are made by opening up the inside diameter contacts. Depth and other measurements can be made with a depth rod built into the instrument’s beam. There are three basic types of caliper that may be found today in a machinist’s tool chest: • Vernier. The vernier caliper is the original design and still the most rugged. Graduated much like a micrometer, it requires the alignment of an etched scale on the vernier plate with an equally spaced scale running the length of the tool’s

handle. Skillful alignment of the tool and interpretation of the reading is necessary to achieve the measurement tool’s stated accuracy. • Dial. A dial caliper is a secondgeneration caliper. Similar in construction to the vernier caliper, this style replaces the vernier scale with a dial indicator. The indicator is fixed to the moveable jaw and engaged with a toothed rack on the body of the unit. The dial, which is typically balanced, meaning it can move in either plus or minus directions from zero, may be graduated in either inch or metric units. The dial caliper is a dual-purpose tool and can make either direct or comparative measurements. To make a comparison, first measure the reference dimension and set the dial indicator to zero. Then measure the dimension to be compared. The indicator will show how much the compared dimension varies from the original (plus or minus). Another useful feature of the dial caliper are jaws that slide past each

other to allow contact points or depth rod Caliper Basics extensions to fit into narrow openings for small ID measurements. • Digital. In the past 25 years the digital caliper has made its way onto the shop floor. The latest designs provide numerous electronic features that make the device easier to use, yet add little in the way of cost. These include: easy switching between inch and metric units on the readout, tolerance indications, digital output to electronic data collection systems, zero setting anywhere along the caliper’s range and retention of the zero setting even when the caliper is turned off. With no moving parts in the readout, the digital caliper is durable, and newer units are even waterproof. Q UA LITY 1 0 1

3 The latest digital calipers provide numerous electronic features that make the device easier to use, yet add little in the way of cost. Source: Mahr Federal Inc.

The versatility of the caliper, along with its range and ease of use, makes it well suited for a multitude of measuring applications. B Y G E O R G E S C H U E T Z

C

alipers are extremely versatile tools for making a wide range of distance measurements, including both outside diameters (OD) and inside diameters (ID). While micrometers are more accurate, they have a limited measurement range, typically several inches. Calipers can span from 2 inches to 4 feet, depending on the length of the scale. External measurements are made by closing the jaws over the piece to be measured, while internal measurements are made by opening up the inside diameter contacts. Depth and other measurements can be made with a depth rod built into the instrument’s beam. There are three basic types of caliper that may be found today in a machinist’s tool chest:

• Vernier. The vernier caliper is the original design and still the most rugged. Graduated much like a micrometer, it requires the alignment of an etched scale on the vernier plate with an equally spaced scale running the length of the tool’s handle. Skillful alignment of the tool and interpretation of the reading is necessary to achieve the measurement tool’s stated accuracy. • Dial. A dial caliper is a secondgeneration caliper. Similar in construction to the vernier caliper, this style replaces the vernier scale with a dial indicator. The indicator is ﬁ xed to the moveable jaw and engaged with a toothed rack on the body of the unit. The dial, which is typically

balanced, meaning it can move in either plus or minus directions from zero, may be graduated in either inch or metric units. The dial caliper is a dual-purpose tool and can make either direct or comparative measurements. To make a comparison, ﬁrst measure the reference dimension and set the dial indicator to zero. Then measure the dimension to be compared. The indicator will show how much the compared dimension varies from the original (plus or minus). Another useful feature of the dial caliper are jaws that slide past each other to allow contact points or depth rod extensions to ﬁt into narrow openings for small ID measurements. • Digital. In the past 25 years the digital caliper has made its way onto the shop ﬂoor. The latest designs provide numerous electronic features that make the device easier to use, yet add little in the way of cost. These include: easy switching between inch and metric units on the readout, tolerance indications, digital output to electronic data collection systems, zero setting anywhere along the caliper’s range and retention of the zero setting even when the caliper is turned off. With no moving parts in the readout, the digital caliper is durable, and newer units are even waterproof.

MEASUREMENT INFLUENCES

Figures a and b illustrate basic OD and ID measurements. Figures c and d illustrate more complex depth and step measurements. Source: Mahr Federal Inc.

22

The biggest problem with calipers is that measurements are subject to variation from one operator to another. Two types of inﬂuences contribute to this variation: “feel” or inconsistent gaging force, and subjective, or psychological, factors. Because the caliper is a contact instrument, sufﬁcient torque must

QUALITY | August 2007

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022_QM0807q101.indd 22

DATA ACQUISITION FOR HANDHELD GAGING, FEBRUARY 2008 When looking for a system to handle data collected by handheld gages, there

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50 YEARS OF QUALITY and trips on the cable, yanking it out of are two choices: wireless and wired. your hands with a lot of force. It could Both systems have their place in induslacerate your hands very easily.” try, and carefully considering the attriAnother problem with butes of each will allow one to cabling is entanglement. “If you make the best decision. c have Paradoxically, one could h five tools in a production make the case that a wireless a and they’re all wired to Data Acquisition area for Handheld Gaging the system’s strength also is its t same multiplexer, they will invariable get tangled,” explains weakness, and that at wired i Wilkinson. “At the end of the system’s strength, too, is its W day, weakness. A wireless system d when they’re all tangled together, someone moves one has no wires—so it has the feat and ture of increased mobility, with gages d they th all come down, which can ruin the tool or injure someone.” that are not tethered to a multiplexer There is the issue of cost. First, while or computer; but this also means that the owner of a wired system has to pay EMI can potentially creep up and ruin for cabling, the owner of a wireless sysor impede an operator’s work. A wired tem has to replace transmitter batteries. system has wires—so it offers an inherSecondly—and more importantly— ent robustness, because EMI cannot are the disparities in initial system cost. compromise an operator’s work; but A wireless system will typically be four cabling also means reduced mobility to five times as expensive as its wired and potential safety issues. counterpart. Wireless systems, then, are As Starrett’s Jeff Wilkinson explains, only advantageous for specific applica“Imagine having a tool with sharp jaws, tions. As Mahr’s George Schuetz points like a slide caliper; now imagine having out, “Wireless transmitters are relatively a tool like that with 20 feet of cabling expensive and are often used in applicarunning from it. You’re holding the tions where cabling is difficult, usually tool delicately and someone walks by |

Q UALITY MEASUREMEN T

|

W

hen looking for a system to handle data collected by handheld gages, there are two choices: wireless and wired. Both systems have their place in industry, and carefully considering the attributes of each will allow one to make the best decision.

WIRELESS SYSTEM COMPONENTS

A standard wireless data acquisition system for handheld gaging usually consists of three things: a transmitter interfaced to the gage, a receiver interfaced to the computer, and software that drives the receiver and collects data from the transmitter, allowing that data to be stored in the computer or transferred to a statistical process control (SPC) program. Both the transmitter and receiver of modern wireless data acquisition systems are often transceivers, meaning that they

Both wireless and wired data acquisition systems for handheld gaging come with distinct advantages. B Y S TE VE W ICHE LE CKI, A S S IS TA N T E D ITO R

send and receive data. Because this functionality allows dialogue between the transmitter and receiver, it provides for the existence of system features that ensure data is received correctly by the computer. Virtually any gage, as long as it is capable of digital output, can be interfaced to a wireless system; the transmitter will connect directly into the gage’s digital output port.

WIRELESS SYSTEMS

Today’s wireless systems can accommodate as many as 120 gages and are capable of transmitting data hundreds of feet under ideal line-of-sight condi-

tions. Furthermore, today’s systems incorporate a robustness and reliability not found in those of the past. This is in part enabled by the common use of transceivers, which helps combat data failure or corruption from electromagnetic interference (EMI) by enabling checks against transmission error. For example, a code can be assigned to a piece of data coming from the transmitter, and if the receiver ﬁnds that the code is corrupt, it will ask the transmitter to re-send that data until uncorrupted data is received. The use of transceivers also makes operator feedback possible; when, for example,

TECH TIPS

Today’s wireless systems can accom-

Wired systems can accommodate

modate as many as 120 gages and are capable of transmitting data hundreds of feet under ideal line-of-sight conditions.

30

many gages and data transmission distance is relative to cable length.

When choosing a system, consider

the environment in which the system is to be used as well as what it is to inspect.

QUALITY | February 2008

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where the gage has to be brought to the part—say in a machine—and the cables become a liability to the operator.” A scenario with few gages and easily handled parts, for example, would be better off with a wired system. However, using a large number of gages in a wired system could offset its initial value. “Wireless systems are not inexpensive. But at a certain point, most of the multiplexers used in wired gaging become pretty expensive,” explains Wilkinson. “So once you get more than eight gages, it makes sense to go with wireless. In a large deployment, wireless is cheaper.” While both wireless and wired data acquisition systems for handheld gaging are viable options in industry, the appropriateness of each is application specific. In terms of component versatility, both systems are equal, providing compatibility with virtually any thirdparty software and gage. Therefore, it is the environment in which the system is to be used as well as what it is to inspect that should guide one’s decision-making process.

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QUALITY 101: MEASURE PRECISELY WITH HAND TOOLS, SEPTEMBER 2008 The sense of touch becomes important when using contact measuring tools. A skilled machinist with a highly developed sense of “feel” can readily detect a difference in contact made by changes in a m dimension as small as d Hand Tools 00.00025 inch. While the aacuteness of the sense of touch varies with o iindividuals, it can be developed with practice d aand proper handling of tools. In the human tools h m hand, the sense of touch is prominent in the fingertips. Therefore, a contact measuring tool is correctly balanced in the hand when held lightly and delicately in such a way that uses the fingers to handle or move the tool. If the tool is clumsily or harshly grasped, the sense of touch or “feel” is greatly reduced. Sight and touch are frequently combined by the skilled worker to estimate measurements finer than the graduated QUALITY 1 0 1

Micrometers combine the double contact of a slide caliper with a precision screw adjustment. Source: The L.S. Starrett Co.

Measure Precisely with

Correct use of hand tools ensures measurement accuracy. BY S C OT T ROBINS ON

D

evelopments in precision measurement have made modern hand tools more accurate and easier to read. Reviewing basic tips on the use of precision instruments can help operators use the tools to their full potential and ultimately save time, reduce errors and increase productivity. Presented here are tips for measuring with three popular hand tools: micrometers, slide calipers and micrometer depth gages.

MICROMETERS

The precision micrometer is the most accurate handheld tool available to skilled operators. Some examples of micrometers include digital, vernier, inside and bench.

Micrometers combine the double contact of a slide caliper with a precision screw adjustment that may be read with great accuracy. To use the instrument, the work piece is placed against the anvil with the left hand while the spindle is turned with the thumb and index ﬁnger of the right hand. The measurement should not be forced, as light contact pressure ensures a correct reading.

MEASURING WITH MICROMETERS

Digital micrometers make readings faster and easier for every machinist, regardless of experience. The framemounted counter saves handling time because it can be read without removing fingers from the thimble or the micrometer from the work.

• Keep the work to be measured and the micrometer anvil and spindle faces clean. • For very ﬁne measurements, the micrometer should be set to zero or to a standard by the operator’s “feel,” by the friction thimble or by the ratchet, whichever is being used. • To minimize any frame ﬂexure inﬂuence, large micrometers should particularly be set to a standard in the same approximate position, app either vertical or o horizontal, in which they will wil be used. • Avoid rushing measuring work as this may result in inaccurate results. • Do not remove work from a micrometer before taki taking a reading. If a reading cannot be sseen without removing the micrometer, micrometer locking the spindle at the ﬁnal setting with the lock nut and sliding the micrometer off the work micr piece by the fra frame will be useful. • If a micrometer micromete has been set to a ﬂat standard, operators can get approximately a 0.0001-inch difference when measuring over a round because the same pressure is being applied to a point or line contact.

ADJUSTING A MICROMETER

• Step 1. To eliminate play in the spindle, back off the thimble, insert the spanner wrench into the adjusting nut and tighten just enough to eliminate play. A spanner wrench will likely be furnished with the micrometer at purchase. • Step 2. To adjust zero reading, clean all dirt or grit from measuring faces by gently closing the spindle to the anvil

SIGHT, TOUCH AND ESTIMATION

The sense of touch becomes important when using contact measuring tools. A skilled machinist with a highly developed sense of “feel” can readily detect a difference in contact made by changes in a dimension as small as 0.00025 inch. While the acuteness of the sense of touch varies with individuals, it can be developed with practice and proper handling of tools. In the human hand, the sense of touch is prominent in the fingertips. Therefore, a contact measuring tool is correctly balanced in the hand when held lightly and delicately in such a way that uses

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QUALITY | September 2008

024_QM0908q101.indd 24

the fingers to handle or move the tool. If the tool is clumsily or harshly grasped, the sense of touch or “feel” is greatly reduced. Sight and touch are frequently combined by the skilled worker to estimate measurements finer than the graduated limits of a tool. For example, on the average micrometer graduated to read in thousandths of an inch, the space between the smallest graduations of the thimble is approximately 1⁄16 inch. Variations in size much smaller than a thousandth of an inch can readily be felt and judged by the eye with reasonable accuracy.

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limits of a tool. For example, on the average micrometer graduated to read in thousandths of an inch, the space between the smallest graduations of the thimble is approximately ¹⁄16 inch. Variations in size much smaller than a thousandth of an inch can readily be felt and judged by the eye with reasonable accuracy.

important that the accuracy of handheld measuring tools be maintained, requiring the tools themselves to be cared for properly. There are two main categories of maintenance for hand measuring tools. The first is in response to everyday use and handling. This assumes that the correct tool is selected in the first place, for example, making sure the IP or Ingress QUALITY 101: PROPER CARE OF Protection Rating is suitable. HANDHELD MEASURING TOOLS, The second type of maintenance JANUARY 2010 is specified by formal, periodic and The nature of quality control meadocumented inspection and calibrasurement is continually changing tion routines. Calibration in response to developments t is in coordinate measuring i most commonly performed in-house, but many machines (CMMs) and other f Proper Care quality programs specify technology-laden metrology q additional calibration at instruments. Nevertheless, a accredited labs. These labs the precision and repeatabila provide calibration traceable ity of handheld dimensional p to measuring tools—calipers, t final standards such as NIST (National Institute of micrometers and gages—are N Standards still heavily relied on throughout ut Standard and Technology). Related to calibration is use of gage blocks— most of manufacturing. And as extremely precise artifacts with a care tolerances of manufactured parts regimen all their own. Q become ever tighter, it is even more Q UA LITY 1 0 1

points—thought by some to be ideal for ripping open boxes. This type of misuse can put burrs on the jaws, maybe too small to see, yet capable of throwing jaws out of stated accuracy. Micrometers are commonly misused in operation. Many micrometers include a ratchet-stop feature to assist in making proper workpiece contact by “slipping” to stop closure of the micrometer faces once proper contact is made. Nevertheless, some users vigorously torque the barrel Calipers are prone to misuse; they usually posses ID jaws even after the ratchet starts that come to very sharp points—thought by some to be ideal clicking; this may cause for ripping open boxes. This type of misuse can put burrs on the spindle face to degrade the jaws, maybe too small to see, yet capable of throwing as it is spun or “ground” jaws out of stated accuracy. Source: Mitutoyo America Corp. into the workpiece. As a result, parallelism between spindle and anvil faces may be aversely affected, thus taking the micrometer out of stated accuracy. The most common mishap to affect any precision measuring tool’s integrity is dropping. Any tool dropped to the ﬂoor—or shocked against hard machine tool or work As tolerances of manufactured parts become ever tighter, surfaces—should be re-calibrated it is even more important that the accuracy of handheld before it is used again. • Preventive care/storage. Preventive measuring tools be maintained, requiring the tools care begins with an assessment of the themselves to be cared for properly. BY TONY POR TI LLO working environment. If measurement tools are used in a harsh environment, for example, with coolant, The second type of maintenance is he nature of quality control meamist, metal chips and debris, prevenspeciﬁed by formal, periodic and docusurement is continually changing tive care can be as simple as wiping in response to developments in coormented inspection and calibration routools clean before storage. dinate measuring machines (CMMs) tines. Calibration is most commonly Wiping down with Kimwipes and other technology-laden metrology performed in-house, but many quality impregnated tissues or with a lintprograms specify additional calibration instruments. Nevertheless, the precifree tissue and denatured alcohol sion and repeatability of handheld at accredited labs. These labs provide will remove whatever material may dimensional measuring tools—calicalibration traceable to ﬁ nal standards be deposited on the tool. This will pers, micrometers and gages—are still such as NIST (National Institute of prevent deposits from solidifying Standards and Technology). Related heavily relied on throughout most of during storage so as to not inhibit to calibration is use of gage blocks— manufacturing. And as tolerances of free movement at next use. manufactured parts become ever tightextremely precise artifacts with a care er, it is even more important that the regimen all their own. Also, calipers and micrometers accuracy of handheld measuring tools should be stored with jaw faces, spinEVERYDAY CARE be maintained, requiring the tools dles and anvils open, gapped slightly themselves to be cared for properly. and not touching. This will prevent • Misuse. The leading cause of damage There are two main categories distortion that can result from the folto hand measuring tools is misuse. of maintenance for hand measurlowing phenomena: Though they may look simple, these ing tools. The first is in response • Any increase in temperature will tools are precision instruments capato everyday use and handling. This cause tools to expand, putting presble of delivering high accuracy: typical assumes that the correct tool is sure on the touching surfaces. dial and digital calipers can measure selected in the first place, for exam• Even with no rise in temperature, to a resolution of 0.0005 inch. Calipers ple, making sure the IP or Ingress the slight pressure of continual conare prone to misuse; they usually posProtection Rating is suitable. tact itself can cause distortion. ses ID jaws that come to very sharp

of Handheld Measuring Tools

T

24

QUALITY | January 2010

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Global Certification-USA LLC P.O. Box 1004, Dayton, OH 45401 (937) 673-6077 Fax: (513) 672-0746 ISO 9001: 2008 ISO 13485 ISO 14000 OHSAS 18001

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Global Registrars Inc. 324 Mineral Ave., P.O. Box 704, Mineral, VA 23117 (540) 894-9570 Fax: (540) 894-9573 [email protected] www.globalregistrars.com ISO 9001: 2008

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Intertek 70 Codman Hill Rd., Boxborough, MA 01719 (800) 810-1195; (978) 929-2100 Fax: (978) 635-8595 [email protected] www.intertek.com/systems-certification ISO 9001: 2008 ISO 13485 ISO 14000 ISO/TS 16949 AS-9100 CE Mark

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IQC LLC P.O. Box 246, Dayton, OH 45401 (937) 223-9000; (937) 673-3732 Fax: (937) 223-9001 ISO 9001: 2008

Notified Body for EU Directives

Documentation Software

Consulting

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Bureau Veritas Certification 3663 N. Sam Houston Pkwy., E., Ste.100, Houston, TX 77032-3612 (800) 937-9311 Fax: (281) 310-3101 ISO 9001: 2008 ISO 14000 ISO/TS 16949 AS-9100 TL 9000

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-DNV Business Assurance 1400 Ravello Dr., Katy, TX 77449 (877) 368-3530; (281) 396-1000 Fax: (281) 396-1903 [email protected] www.dnvcert.com OR www.dnvtraining.com ISO 9001: 2008 ISO 14000 ISO/TS 16949 AS-9100 TL 9000 CE Mark

Consulting

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American Systems Registrar 5281 Clyde Park Ave., Ste. 1, Wyoming, MI 49509 (888) 891-9002 Fax: (616) 942-6409 [email protected] www.asrworldwide.com ISO 9001: 2008 ISO 13485 ISO 14000 ISO/TS 16949 AS-9100

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The American Association for Laboratory Accreditation 5301 Buckeystown Pike, Ste. 350, Frederick, MD 21704 (301) 644-3248 [email protected] OR [email protected] ISO 17025

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QUALITY CERTIFICATION & REGISTRATION GUIDE

Auditing

Alliance International Registrar LLC 47585 Scenic Cir., N., Canton, MI 48188 (734) 667-5399 Fax: (317) 669-2103 [email protected] www.allianceregistrar.com ISO 9001: 2008 ISO 13485 ISO 14000 ISO/TS 16949 ISO 17025 AS-9100 CE Mark ISO 18001:2007 ISO 27001:2005

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Training

Company/Standard Name ABS Quality Evaluations Inc. 16855 Northchase Dr., Houston, TX 77060 (281) 673-2843 Fax: (281) 673-2844 [email protected] www.abs-qe.com ISO 9001: 2008 ISO 13485 ISO 14000 ISO/TS 16949 AS-9100 TL 9000 ISO 28000 ISO 28000; AS 9120; ISO/IEC 27001; ISO/TS 29001; RCMS,; RC 14001; OHSAS 18001; SA 8000, IECQQC 080000; ANSI/ESD S20.20; PED

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TRUaccuracy™ TECHNOLOGY

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Auditing

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Company/Standard Name QCS Inc./DAS Certification (USA) 6161 Savoy Ln., Ste. 455, Houston, TX 77036 (713) 789-0885; (281) 565-2447 Fax: (713) 481-8434 [email protected] www.dascertificationusa.com ISO 9001: 2008

Training

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Company 9000 Advisers 290 Edgewater Dr., Middleton, TN 38052 (731) 376-8558 www.9000advisers.com Absolute Clarity & Calibration LLC 109 Main St., Terryville, CT 06786 (860) 583-0502 Fax: (860) 314-1851 Accu-Check Instrument Service Inc. 3160 W. Fair Ave., Lancaster, OH 43130 (740) 654-0500 Fax: (740) 654-3899 Advanced Inspection Services 15150 25th Ave. N., Ste. 200, Plymouth, MN 55447 (763) 473-2258 Fax: (763) 249-8150 [email protected] www.advancedinspect.com OR www.gagesite.com Advanced Measurement Labs Inc. 15840 W. Monte St., Ste. B 109, Sylmar, CA 91342 (818) 833-4444 Fax: (818) 833-7779 [email protected] AIC Quality Services LLC P.O. Box 37361, Houston, TX 77237 (713) 443-4373 American Standards Testing Bureau Inc. P.O. Box 583, New York, NY 10274-0583 (800) 221-5170; (212) 943-3160 Fax: (212) 825-2250 [email protected] www.containertechnologylabs.com AMETEK 8600 Somerset Dr., Largo, FL 33773 (800) 527-9999; (727) 538-6000 Fax: (727) 539-6882 [email protected] www.chatillon.com OR www.lloyd-instruments.com Applied Technical Services Inc. 1049 Triad Ct., Marietta, GA 30062 (770) 423-1400 Fax: (770) 424-6415 Arcadia Aerospace Industries LLC 28000 Airport Rd., A-11, Mooney Ave., Bldg. 110, Punta Gorda, FL 33982 (800) 370-2821 Fax: (941) 205-5701 Automated Precision Inc. 15000 Johns Hopkins Dr., Rockville, MD 20850 (240) 268-0400; (800) 537-2720 Fax: (301) 990-8648 [email protected] www.apisensor.com Automation Innovation Inc. 4604 Eastbrae Ct., Fuquay-Varina, NC 27526 (919) 557-6824 [email protected] OR [email protected] www.auto-in.com OR www.threadinspection.com Bobier Metrology Solutions G4163 Corunna Rd., Flint, MI 48532 (800) 288-2871; (810) 732-4030 Fax: (810) 732-3909 BSI Group America Inc. 12110 Sunset Hills Rd., Ste. 200, Reston, VA 20190 (800) 862-4977; (703) 437-9000 [email protected] www.bsiamerica.com Buehler 41 Waukegan Rd., P.O. Box 1, Lake Bluff, IL 60044 (800) BUE-HLER; (847) 295-6500 Fax: (847) 295-7979 Cal Lab Co. Inc. 17035 Westview Ave., South Holland, IL 60473 (800) 373-1759 Fax: (708) 596-5802

CMM First Article Inspection

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Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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Video Equipment

Vacuum

Torque

Tensile Testers

Temperature

Surface Plates

Spring/Compression

Scales/Balances

Pressure/Flow

Optical Equipment

Microscopes

Mass

Magnetic Particle Machines

Load Cells

Levels

Leak Testers

Hard Gage

Hand Gages

Gage Repair

Gage Blocks

Form/Shape/Surface/Contour

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

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Dead Weight Testers

CMM First Article Inspection

Company Capture 3D Inc. 3505 Cadillac Ave., F1, Costa Mesa, CA 92626 (714) 546-7278; (281) 338-7226 Fax: (248) 426-9001; (860) 940-7234 [email protected] OR [email protected] www.capture3d.com Carl Zeiss Industrial Metrology LLC 6250 Sycamore Ln., N., Maple Grove, MN 55369 (800) 327-9735; (763) 744-2400 Fax: (763) 533-0219 Certified Comparator Products 838 Distribution Dr., Beavercreek, OH 45434 (937) 426-9677 Fax: (937) 426-4816 CGI Inc. 15161 Technology Dr., Eden Prairie, MN 55344 (952) 937-2005; (800) 207-4318 Fax: (952) 937-3018 Cincinnati Precision Instruments 253 Circle Freeway Dr., Cincinnati, OH 45246 (800) 686-3730; (513) 874-2122 Fax: (513) 874-2536 [email protected] www.cpi1stop.com Clark Instrument Inc. 46590 Ryan Ct., Novi, MI 48377 (248) 669-3100 Fax: (248) 669-1199

CNC Machining Centers

CMMs •

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Hardness Testers

CALIBRATION SERVICES

SERVICES GUIDE

www.qualitymag.com • •

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Other

Thread Inspection

Surface Finish Analysis

Spring Testing

Reverse Engineering

Repair Services

Part and Tool Inspection

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Noncontact Inspection

NDT

Metallurgy

Mechanical Testing

Materials Testing

Leak Testing

Laser Inspection

ID/OD Measurement

Gear Inspection

Form and Roundness Testing

First Article Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Dimensional Inspection

CMM Inspection

Capability Studies & Statistical Analysis, PPAP

Capability Studies & Statistical Analysis, Gage R&R

Capability Studies & Statistical Analysis, SPC

Calibration Services

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Six Sigma

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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Vacuum

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Torque

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Pressure/Flow

Optical Equipment

Microscopes

Mass

Magnetic Particle Machines

Load Cells

Levels

Leak Testers

Hard Gage

Hand Gages

Gage Repair

Gage Blocks

Form/Shape/Surface/Contour

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

Dead Weight Testers

CNC Machining Centers

Company Cooper Instruments 400 Belle Air Ln., P.O. Box 3048, Warrenton, VA 20188 (800) 344-3921; (540) 349-4746 Creaform 220 E. Delaware Ave., Newark, DE 19711 (302) 444-6696 Fax: (418) 833-9588 [email protected] www.creaform3d.com C.S.C. Force Measurement Inc. P.O. Box 887,84 Ramah Cir., N., Agawam, MA 01001-0887 (800) 866-3672; (413) 789-3086 Fax: (413) 789-3598 [email protected] www.cscforce.com DataNet Quality Systems 29200 Northwestern Highway, 3rd Floor, Southfield, MI 48034 (248) 357-2200 Fax: (248) 357-4933 [email protected] winspc.com Detroit Testing Machine Co. 46590 Ryan Ct., Novi, MI 48377 (248) 669-3100 Fax: (248) 669-1199 Digital Measurement Metrology 26 Automatic Rd., Unit 4, Brampton, Canada L6S 5N7 (866) 960-9400 www.dmm.ca OR www.calibrationservices.ca Dimensional Measurement Inc. 46989 Liberty Dr., Wixom, MI 48393 (248) 960-8801 [email protected] www.dimensionalmeasure.com DNV Business Assurance 1400 Ravello Dr., Katy, TX 77449 (877) 368-3530; (281) 396-1000 Fax: (281) 396-1903 [email protected] www.dnvcert.com OR www.dnvtraining.com Dorsey Metrology International 53 Oakley St., Poughkeepsie, NY 12601 (845) 454-3111 Fax: (845) 454-3888 www.dorseymetrology.com Dynamic Technology Inc. 3201 W. Royal Ln., Ste. 150, Irving, TX 75063 (214) 723-5600 Eastern Applied Research 6614 Lincoln Ave., Lockport, NY 14094-6109 (716) 201-1115 Fax: (716) 201-1119 EMI Gage 28W144 Industrial Ave., Ste. 100, Lake Barrington, IL 60010 (847) 277-7511 Fax: (847) 277-7911 Engineered Work Systems P.O. Box 82262, Rochester, MI 48308 (248) 652-1741; (248) 895-0725 EtQ Inc. 399 Conkin St., Ste. 208, Farmingdale, NY 11735 (516) 293-0949; (800) 354-4476 Gage Services Inc. 40120 Grand River Ave., Novi, MI 48375 (800) 280-7592; (248) 476-8350 Fax: (248) 476-8535 [email protected] OR [email protected] www.gageservices.com OR www.gageservices.net GHR Associates 103 Kakeout Rd., Butler, NJ 07405 (973) 838-8915 Fax: (973) 838-8915

CMM First Article Inspection

CMMs

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Hardness Testers

CALIBRATION SERVICES

SERVICES GUIDE

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Other

Thread Inspection

Surface Finish Analysis

Spring Testing

Repair Services

Part and Tool Inspection

Noncontact Inspection

NDT

Metallurgy

Materials Testing

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Leak Testing

Laser Inspection

ID/OD Measurement

Gear Inspection

Form and Roundness Testing

First Article Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Dimensional Inspection

CMM Inspection

Capability Studies & Statistical Analysis, PPAP

Capability Studies & Statistical Analysis, Gage R&R

Capability Studies & Statistical Analysis, SPC

Calibration Services

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Six Sigma

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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Other

Video Equipment

Vacuum

Torque

Tensile Testers

Temperature

Surface Plates

Spring/Compression

Scales/Balances

Pressure/Flow

Optical Equipment

Microscopes

Mass

Magnetic Particle Machines

Load Cells

Levels

Leak Testers

Hard Gage

Hand Gages

Gage Repair

Gage Blocks

Form/Shape/Surface/Contour

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

Dead Weight Testers

CNC Machining Centers

Company Global Certification-USA LLC P.O. Box 1004, Dayton, OH 45401 (937) 673-6077 Fax: (513) 672-0746 Harpco Systems Inc. 29445 Beck Rd., Ste. A205, Wixom, MI 48393-3348 (248) 374-1718 www.harpcosystems.com -Hemco Gage 455 Douglas Ave., Holland, MI 49424 (800) 959-7413; (616) 396-4604 Fax: (616) 396-0413 [email protected] www.hemcogages.com Hexagon Metrology Services Inc. 250 Circuit Dr., North Kingstown, RI 02852 (800) 274-9433; (314) 276-2387 Fax: (314) 878-4895 Hommel-Etamic America 1505 W. Hamlin Rd., Rochester Hills, MI 48309 (248) 853-5888 Fax: (248) 853-1505 [email protected] www.hommel-etamic.com Industrial Imaging Systems LLC 4444 Junipero Serra, Ste. 200, San Jose, CA 95129 (408) 408-4084; (408) 408-4087 Fax: (408) 408-4087; (408) 777-0108 -InfinityQS International Inc. 14900 Conference Center Dr., Chantilly, VA 20151 (800) 772-7978; (703) 961-0200 Fax: (703) 961-1923 [email protected] www.infinityqs.com International Quality Institute N30W5030 Landmark Dr., Cedarburg, WI 53012-2910 (262) 375-8868 IQC LLC P.O. Box 246, Dayton, OH 45401 (937) 223-9000; (937) 673-3732 Fax: (937) 223-9001 IQL Independent Quality Labs Inc. 15 Gray Ln., Ste. #401, Ashaway, RI 02804-1209 (401) 539-8510; (866) 549-2920 Fax: (401) 539-0572 ISOQual International Corp. 24 Mayfair St., Norwood, MA 02062 (781) 762-6664 -Laboratory Testing Inc. 2331 Topaz Dr., Hatfield, PA 19440 (800) 219-9095; (215) 997-9080 Fax: (800) 219-9096; (215) 997-9511 [email protected] www.labtesting.com -Ledford Gage Laboratory Inc. 227 Industrial Dr., P.O. Box 100, Mulvane, KS 67110-0100 (316) 777-9300; (800) 237-GAGE (4243) Fax: (316) 777-2220 [email protected] OR [email protected] www.ledfordgage.com -Mahr Federal Inc. 1144 Eddy St., Providence, RI 02905 (800) 343-2050 Fax: (401) 784-3246 [email protected] www.mahr.com Master Metrology 1041 Cromwell Bridge Rd., Towson, MD 21286 (800) 532-8020 Metrologic Group Services Inc. 28064 Center Oaks Ct., Wixom, MI 48393 (248) 504-6200 Fax: (248) 504-5430 -Meyer Gage Co. Inc. 230 Burnham St., South Windsor, CT 06074 (860) 528-6527; (888) 746-4243 Fax: (860) 528-1428 [email protected] www.meyergage.com

CMM First Article Inspection

CMMs

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Hardness Testers

CALIBRATION SERVICES

SERVICES GUIDE

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Thread Inspection

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Surface Finish Analysis

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Spring Testing

NDT

Metallurgy

Mechanical Testing

Materials Testing

Leak Testing

Gear Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Form and Roundness Testing

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First Article Inspection

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Dimensional Inspection

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CMM Inspection

Capability Studies & Statistical Analysis, PPAP

Capability Studies & Statistical Analysis, Gage R&R

Capability Studies & Statistical Analysis, SPC

Calibration Services

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Six Sigma

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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Video Equipment

Vacuum

Torque

Tensile Testers

Temperature

Surface Plates

Spring/Compression

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Scales/Balances

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Pressure/Flow

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Optical Equipment

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Microscopes

Hardness Testers

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Mass

Hard Gage

•

Magnetic Particle Machines

Hand Gages

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Load Cells

Gage Repair

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Levels

Gage Blocks

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

Dead Weight Testers

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Form/Shape/Surface/Contour

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CNC Machining Centers

Company Minitab Inc. 1829 Pine Hall Rd.,Quality Plaza, State College, PA 16801-3008 (800) 448-3555; (814) 238-3280 www.minitab.com Mitutoyo America Corp. 965 Corporate Blvd., Aurora, IL 60502 (630) 820-9666; (888) 648-8869 Fax: (630) 978-3501 [email protected] www.mitutoyo.com Nikon Metrology Inc. 12701 Grand River Rd., Brighton, MI 48116 (810) 220-4360 Fax: (810) 220-4300 [email protected] www.nikonmetrology.com Perry Johnson Consulting Inc. 5000 Town Center, Ste. 2002, Southfield, MI 48075 (888) 248-0256; (248) 519-2588 Fax: (248) 247-3366 [email protected] OR [email protected] www.pjcinc.com Pinnacle Partners Inc. 36 Rivers Run Way, Oak Ridge, TN 37830 (865) 482-1362 Fax: (865) 483-7451 [email protected] www.pinnaclepartnersinc.com QC Group Inc., The 5950 Clearwater Dr., Ste. 300, Minnetonka, MN 55343 (952) 895-1150 Fax: (952) 895-1152 Q-PLUS Labs 13765-E Alton Pkwy., Irvine, CA 92618 (949) 380-7758 Fax: (949) 380-7790 [email protected] OR [email protected] www.qpluslabs.com Quad Group Inc. 1815 S. Lewis St., Spokane, WA 99224 (800) 342-2430; (509) 458-4558 Fax: (509) 458-4555 [email protected] www.quadgroupinc.com Quality Vision Services Inc. 1175 North St., Rochester, NY 14621-4942 (866) 815-6618 Fax: (585) 506-4307 R & R Gage 6669-G Peachtree Industrial Blvd., Norcross, GA 30092 (770) 409-9801 R. L. Schmitt Co. Inc. 34506 Glendale, Livonia, MI 48150 (877) 777-9310; (734) 525-9310 Fax: (734) 525-1616 www.rlschmitt.com Renishaw Inc. 5277 Trillium Blvd., Hoffman Estates, IL 60192 (847) 286-9953 Fax: (847) 286-9974 Restor Metrology 921 Venture Ave, Leesburg, FL 34748 (877) 220-5554 Fax: (866) 202-9554 Rotronic Instrument Corp. 135 Engineers Rd., Ste. 150, Hauppauge, NY 11788 (631) 427-3898; (800) 628-7101 Fax: (631) 427-3902

CMM First Article Inspection

CMMs

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Leak Testers

CALIBRATION SERVICES

SERVICES GUIDE

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Other

Thread Inspection

Surface Finish Analysis

Spring Testing

Reverse Engineering

Repair Services

Part and Tool Inspection

Noncontact Inspection

NDT

Metallurgy

Mechanical Testing

Materials Testing

Leak Testing

Laser Inspection

ID/OD Measurement

Gear Inspection

Form and Roundness Testing

First Article Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Dimensional Inspection

CMM Inspection

Capability Studies & Statistical Analysis, PPAP

Capability Studies & Statistical Analysis, SPC

Calibration Services

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Six Sigma

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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SAI Global 2 Summit Park Dr., Ste. 425, Cleveland, OH 44131 (800) 247-0802 (216) 654-0900 [email protected] www.saiglobal.com Scantek Inc. 6430 #C, Dobbin Rd., Columbia , MD 21045 (410) 290-7726; (800) 224-3813 Sciemetric Instruments Inc. 359 Terry Fox Dr., Ste. 100, Ottawa, Canada K2K 2E7 (613) 254-7054 www.sciemetric.com SPC Press/Statistical Process Controls Inc. 5908 Toole Dr., Ste. C, Knoxville, TN 37919 (865) 584-5005; (800) 545-8602 SRI Quality System Registrar 300 Northpointe Cir., Ste. 304, Seven Fields, PA 16046 (724) 934-9000 Fax: (724) 935-6825 [email protected] www.sriregistrar.com Sun-Tec Corp. 46590 Ryan Ct., Novi, MI 48377 (248) 669-3100 Fax: (248) 669-1199 Thread Check Inc. 390 Oser Ave., Hauppauge, NY 11788 (631) 231-1515; (800) 767-7633 Fax: (631) 231-1625; (800) 767-2034 [email protected] www.threadcheck.com Touchstone Measurement Services LLC 2529 Commerce Dr., Ste. F, Kokomo, IN 46902 (765) 454-5888 [email protected] www.touchstone.net Troemner LLC 201 Wolf Dr.,P.O. Box 87, Thorofare, NJ 08086 (800) 352-7705 [email protected] www.troemner.com United Testing Systems Inc. 5171 Exchange Dr., Flint, MI 48507 (800) 578-2800; (810) 732-2800 Fax: (810) 732-2872 -Western Gage Corp. 3316-A Maya Linda, Camarillo, CA 93012-8059 (800) 423-5062 Fax: (805) 445-7530 [email protected] www.westerngage.com Yokogawa Corp. of America 2 Dart Rd., Newnan, GA 30265 (800) 888-6400 Fax: (770) 251-2080 [email protected] www.yokogawa-usa.com OR www.yokogawa.com/us YXLON 3400 Gilchrist Rd., Akron, OH 44260-1221 (330) 798-4800 Fax: (330) 784-9854 www.yxlon.com Zygo Corp. Laurel Brook Rd., Middlefield, CT 06455 (860) 347-8506 Fax: (860) 347-3869 [email protected] www.zygo.com

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QUALITY MANAGEMENT SERVICES GUIDE LEGEND Quality Systems Consulting

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Large-Scale Scanning

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X-Ray Fluorescence (XRF)

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Certification/Registration

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Volumetric Error Compensation, Machine Tool Clibration/Repair

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SPC Software

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Coating Thickness Measurement

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Failure Modes and Effects Analysis

QUALITY | July 2011

Other 12

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Video Equipment

Vacuum

Torque

Tensile Testers

Temperature

Surface Plates

Spring/Compression

Scales/Balances

Pressure/Flow

Optical Equipment

Microscopes

Mass

Magnetic Particle Machines

Load Cells

Levels

Leak Testers

Hard Gage

Hand Gages

Gage Repair

Gage Blocks

Form/Shape/Surface/Contour

Force

Film/Paint Thickness

Electrical/Electronic

Durometers

Dead Weight Testers

CNC Machining Centers

Company

CMM First Article Inspection

CMMs

✪ View product spec sheets for these companies at www.qualitymag.com/servicesguide

Hardness Testers

CALIBRATION SERVICES

SERVICES GUIDE

www.qualitymag.com

• Six Sigma

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www.qualitymag.com

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Implementation, Consulting and Training

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Model Based Inspection

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NVH, Torque, Weld

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Check Fixtures

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Sound and Vibration Instruments and Transducers

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Vision System Inspection

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Other

Thread Inspection

Surface Finish Analysis

Spring Testing

Reverse Engineering

Repair Services

Part and Tool Inspection

Noncontact Inspection

NDT

Metallurgy

Mechanical Testing

Materials Testing

Leak Testing

Laser Inspection

ID/OD Measurement

Gear Inspection

Form and Roundness Testing

First Article Inspection

Failure Analysis

Environmental Testing

Electrical/Electronic

Dimensional Inspection

CMM Inspection

Calibration Services

•

Accelerated Stress Testing

3-D Measurement

Other

Total Quality Management

Suggestion Systems

Strategic Quality Planning

Statistical Process Control

Quality Management Systems

Quality Function Deployment

Problem Solving

Lean

CE Mark

Benchmarking

Baldrige Award

MANAGEMENT SERVICES MEASUREMENT/TEST/INSPECTION SERVICES

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✪ View product spec sheets for these companies at www.qualitymag.com/softwareselector

Company/Software Name Accupoint Software 241 W. Federal St., Youngstown, OH 44503 (800) 563-6250 Fax: (330) 746-6863 InterLink QES Quality, Environmental & Safety Management Software 10.0.0.3 AcquiData Inc. P.O. Box 83,Shared Services Ctr., South Woodstock, CT 06267 (860) 910-4747 Fax: (860) 910-4747 Testream/CS Product Quality Automation System Advanced Systems & Designs Inc. 360 E. Maple Rd., Ste. L, Troy, MI 48083 (248) 370-9919 Fax: (248) 370-9921 SPC1+ Enterprise Altegra 1902 Wright Pl., Ste. 200, Carlsbad, CA 92008 (760) 438-7403 Fax: (760) 438-4013 [email protected] www.altegra.com GageManager - Powerful and Affordable Calibration Scheduling MSA, Gage Inventory Management PlantNet SPC - SPC, Tool Change Scheduling, Downtime Tracking for Machine Shops AQA Co. Inc. P.O. Box 90516, Pasadena, CA 91109 (626) 796-9000 Fax: (818) 790-9015 [email protected] OR [email protected] www.isoxp.com ISOXpress Document Control and Quality Management Software 2011 ASDQMS 360 E. Maple Rd., #L, Troy, MI 48083 (248) 370-9919 Fax: (248) 370-9921 SPC1+ Enterprise AssetSmart 2800 28th St., Ste. 109, Santa Monica, CA 90405 (310) 450-2566 Fax: (310) 450-1311 [email protected] OR [email protected] www.assetsmart.com Asset Management 360 SMART/CMS - Calibration Management System SMART/ENCATS - Enterprise Catalog System AutoData Systems 6111 Blue Circle Dr., Minneapolis, MN 55343 (800) 662-2192; (952) 938-4710 Fax: (952) 938-4693 AutoData ExpertScan with NetE-nable 2.0.15 BellHawk Systems Corp. 2 Jacques Pkwy., Millbury, MA 01527 (508) 865-8070 x301 [email protected] www.bellhawk.com BellHawk Inventory and WIP Tracking and Traceability Blue Mountain Quality Resources Inc. P.O. Box 830, State College, PA 16804-0830 (800) 982-2388 Fax: (814) 234-7077 Blue Mountain Regulatory Asset Manager R3 BSI Group America Inc. 12110 Sunset Hills Rd., Ste. 200, Reston, VA 20190 (888) 429-6178; (703) 437-9000 Fax: (703) 437-9001 www.bsiamerica.com Entropy BuildIT Software & Solutions Ltd. 4999 St. Catherine St., W., Ste. 308, Montreal, Canada H3Z 1T3 (514) 369-4055; (888) 687-2348 Fax: (514) 369-2348 [email protected] www.builditsoftware.com Build!IT

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Media

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Computing Platforms

CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Company/Software Name Capture 3D Inc. 3505 Cadillac Ave., F1, Costa Mesa, CA 92626 (714) 546-7278; (281) 338-7226 Fax: (248) 426-9001; (860) 940-7234 Free GOM Inspect GOM Inspect Professional Carl Zeiss Industrial Metrology LLC 6250 Sycamore Ln., N., Maple Grove, MN 55369 (763) 744-2400; (800) 327-9735 Fax: (763) 533-0219 CALYPSO Metrology Software 5.0 -CEBOS 5936 Ford Ct., Ste. 203, Brighton, MI 48116 (810) 534-2222 x4 Fax: (810) 534-0131 [email protected] www.cebos.com CEBOS MQ1 -CyberMetrics Corp. 1523 W. Whispering Wind Dr., Ste. 100, Phoenix, AZ 85085 (800) 777-7020; (480) 922-7300 Fax: (480) 922-7400 [email protected] www.cybermetrics.com Calibration Label Kit CalPro Step-by-step Calibration Procedures CyberSensor Temperature and Humidity Monitor FaciliWorks 8i Hosted Calibration & CMMS/ Enterprise Asset Mgmt. 8.6 FaciliWorks 8i Server Calibration & CMMS/ Enterprise Asset Mgmt. 8.6 FaciliWorks Desktop CMMS/Enterprise Asset Mgmt. 8.1 FaciliWorks PDA Software GAGEtrak Calibration Management Software 6.7 GAGEtrak PDA Software GAGEtrak Portable Calibration Solution GAGEtrak Total Calibration Solution SUPPLIERtrak Supplier Quality Assurance Software 4.6 DataLyzer International Inc. 1857 E. West Maple Rd., Walled Lake, MI 48390 (248) 960-3535; +31-40-2940980 Fax: (248) 960-3539 DataLyzer Spectrum Gage Management DataLyzer Spectrum SPC SPC Quickie SPC Wizard DataNet Quality Systems 29200 Northwestern Highway, 3rd Floor, Southfield, MI 48034 (248) 357-2200 Fax: (248) 357-4933 [email protected] www.winspc.com QualTrend WinSPC Deacom Inc. 950 W. Valley Rd., Ste. 3000, Wayne, PA 19087 (610) 971-2278 Fax: (610) 971-2279 [email protected] www.deacom.net DEACOM Enterprise Resource Planning (ERP) Software Dimensional Metrology Standards Consortium 1228 Enclave Cir., #301, Arlington, TX 76011 (817) 461-1092; (817) 683-6228 Fax: (817) 461-4845 [email protected] OR [email protected] www.dmisstandards.org OR www.dmis.org Dimensional Measuring Interface Standard DMIS 5.2 (ANSI and ISO Standard)

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Company/Software Name Faro Technologies Inc. 125 Technology Pk., Lake Mary, FL 32746 Fax: (407) 333-4181 CAM2 Measure Gagemaker LP P.O. Box 87709, Houston, TX 77287 (713) 472-7360 Fax: (713) 472-7241 [email protected] www.gagemaker.com TDWIN GrayTech Systems Inc. 2950 New Macland Rd., Powder Springs, GA 30127 (770) 499-1510 Fax: (770) 422-8546 RealSPC H & H Servicco Corp. P.O. Box 9340, North St. Paul, MN 55109-0340 (651) 777-0152 [email protected] www.samplingplans.com Acceptance Sampling Plan Designer (TP105/TP414) 3.0 Harold S. Haller & Co. 5 Ashley Ct., Cleveland, OH 44116-2381 (440) 895-0775; (440) 364-6005 HITS (EDO-MCA-MPO-SVA-CCA) Haller Information Technology System Version 3 Harpco Systems Inc. 29445 North Beck Rd., Ste. A205, Wixom, MI 48393 (248) 374-1718 Fax: (248) 374-0022 [email protected] www.harpcosystems.com Quality Plus 4.1 Hertzler Systems Inc. 2312 Eisenhower Dr. N., Goshen, IN 46526 (574) 533-0571 Fax: (574) 533-3885 Gain Seeker Suite Hexagon Metrology Inc. 250 Circuit Dr., N. Kingstown, RI 02852 (800) 274-9433; (401) 886-2000 Fax: (401) 886-2727 PC-DMIS I & R Partners Inc. 1048 Edgewater Cir., Gallatin, TN 37066 (615) 777-9372; (615) 394-3243 Fax: (615) 822-5087 GaugeFlex Data Collection Suite IBS America 24 Hartwell Ave., Lexington, MA 02421 (781) 862-9002 Fax: (781) 862-9003 [email protected] www.ibs-us.com CompliantPro QSYS Professional -InfinityQS International 14900 Conference Center Dr., Chantilly, VA 20151 (800) 772-7978; (703) 961-0200 Fax: (703) 961-1923 [email protected] www.infinityqs.com Data Management System (DMS) Dynamic Scheduler ProFicient 4 InnovMetric Software 2014 Cyrille-Duquet, #310, Quebec City, Canada G1N 4N6 (418) 688-2061 Fax: (418) 688-3001 [email protected] www.innovmetric.com PolyWorks/Inspector PolyWorks/Inspector Probing

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CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Company/Software Name Intelex Technologies 905 King St. W., Ste. 600, Toronto, Canada M6K 3G9 (416) 599-6009 www.intelex.com Intelex Compliance Management Intelex Customer Management Intelex Document Control Intelex Integrated Management System Intelex ISO 9001 Management Intelex Quality Management System Intelex Quality Nonconformances & Product Defect Tracking Intelex Quality Objectives & Targets Intelex Quality Policy Intelex Supplier Corrective Actions Intelex Supplier Nonconformance Intelex Supplier Performance Management System Intelex Training Management Interax Group 66 Richmond St.,P.O. Box 23, Amherstburg, Canada N9V 2Z2 (800) 884-3160 Fax: (866) 778-0006 [email protected] www.interaxgrp.com Paradigm 3 Compliance & Document Control Software James D. Meadows & Assoc. Inc. 170 E. Main, Ste. D-137, Hendersonville, TN 37075 (615) 824-8644 Fax: (615) 824-5262 www.geotolmeadows.com Geometric Dimensioning and Tolerancing (GD&T) per ASME Y14.5M-1994 Launsby Consulting 2830 Bethune Ct., Colorado Springs, CO 80920 (719) 282-1143 Fax: (719) 282-3099 [email protected] www.launsby.com DOE Wisdom 6.4.2 Lennox Hill Ltd. P.O. Box 50490, London, England, U.K. W8 9ES +44 5601 567 990 [email protected] www.lennoxhill.co.uk isoTracker - Document Control isoTracker - Quality Management Software Lighthouse Systems Inc. 6780 Pittsford-Palmyra Rd., Bldg. 3, Fairport, NY 14450 (585) 223-0600 Fax: (585) 223-0620 [email protected] www.lighthousesystems.com Shopfloor-Online 4.9 Lyons Information Systems Inc. 2832 Super Sport Ln., Raleigh, NC 27603 (919) 771-1510; (866) 351-4287 Fax: (919) 341-4304 Lyons Quality Audit Tracking System (LQATS) Manedge Software P.O. Box 29063, Austin, TX 78755 (800) 352-8852; (512) 257-3311 Carmen Documents 5.5 Marposs Corp. 3300 Cross Creek Pkwy., Auburn Hills, MI 48326 (248) 370-0404 Fax: (248) 370-0621 [email protected] www.marposs.com Machine Tool 3D Shape Inspector Software Quick SPC for Windows

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CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Company/Software Name Metrologic Group Services Inc. 28064 Center Oaks Ct., Wixom, MI 48393 (248) 504-6200 Fax: (248) 504-5430 Metrolog XG, SILMA XG, Metrolog V5, SILMA V5 Micro-Vu Corp. 7909 Conde Ln., Windsor, CA 95492 (707) 838-6272 Fax: (707) 838-3985 www.microvu.com InSpec Metrology Software 2.91.0241 MicroRidge Systems Inc. P.O. Box 3249, Sunriver, OR 97707-0249 (541) 593-1656 Fax: (541) 593-5652 [email protected] www.microridge.com WedgeLink Software Keyboard wedge Minitab Inc. 1829 Pine Hall Rd., Quality Plaza, State College, PA 16801 (800) 448-3555; (814) 238-3280 Fax: (814) 238-4383 [email protected] www.minitab.com Minitab Statistical Software 16 Quality Companion by Minitab 3 Quality Trainer by Minitab Mitutoyo America Corp. 965 Corporate Blvd., Aurora, IL 60502 (630) 820-9666; (888) 648-8869 Fax: (630) 820-3418 [email protected] www.measurlink.com MeasurLink Gage Management MeasurLink Gage R&R MeasurLink Process Analyzer MeasurLink Process Manager MeasurLink Real Time MeasurLink Real Time PLUS Optical Gaging Products (OGP) 850 Hudson Ave., Rochester, NY 14621 (585) 544-0400; (800) 647-4243 Fax: (585) 544-8092 SmartProfile Pilgrim Software Inc. 2807 W. Busch Blvd., Tampa, FL 33618 (813) 915-1663 Fax: (813) 915-1948 SmartSolve -PQ Systems 210 B East Spring Valley Rd., Dayton, OH 45458 (800) 777-3020 Fax: (937) 885-2252 [email protected] www.pqsystems.com CHARTrunner 3.6 GAGEpack 9.0 SQCpack 6.5 -Proquis 1015 West Wise Rd., Ste. 200, Schaumburg, IL 60193 (847) 278-3230; (877) 876-3430 Fax: (847) 278-3237 [email protected] www.proquis.com Allclear 2010 Analyzer 8 Allclear 2010 Flowcharter 8 Allclear 2010 Orgcharter 8 Allclear Pro 8 Proquis Enterprise Proquis On Demand Q-PLUS Labs 13765-E Alton Pkwy., Irvine, CA 92618 (949) 380-7758 Fax: (949) 380-7790 [email protected] www.qpluslabs.com 2D Profile Pro 1.8

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QUALITY | July 2011

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Computing Platforms

CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Company/Software Name QI Macros Lean Six Sigma SPC Software for Excel 2253 S. Oneida St., Ste. 3D, Denver, CO 80224 (888) 468-1537; (303) 756-9144 Fax: (888) 468-1536; (303) 756-3107 [email protected] OR [email protected] www.qimacros.com QI Macros Lean Six Sigma SPC Software for Excel 2011 Quality America Inc. 1984 N. Kolb Rd., Tucson, AZ 85715-4005 (800) 722-6154; (520) 722-6154 Fax: (520) 722-6705 [email protected] www.qualityamerica.com Q-Pulse QMS SPC Explorer Qualtrax Inc. 105 Industrial Dr., Christiansburg, VA 24073 (800) 277-3077 Fax: (540) 382-4701 Qualtrax R&R Fixtures / R&R Sales & Engineering P.O. Box 161, Grand Haven, MI 49417 (616) 847-6045 Fax: (616) 847-6082 FixtureBuilder

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CD-ROM/DISK Internet APQP/PPAP Analysis/DOE CMM Programming/Simulation Corrective Action Data Collection and Mining DMIS/Computer and CAD-Based Inspection Document Control Flowcharting/Process Mapping Failure Mode and Effects Analysis (FMEA) Gage Calibration/Management Gage R&R ISO 13485 ISO 17025 ISO/TS 16949 ISO 9000 Series QS-9000 Quality Alert Notification Quality Function Development (QFD) Shape Metrology Six Sigma SPC/SQC and Statistical Analysis Total Quality Management Training Other Linux MAC MS/DOS, PC/DOS Unix Windows CE/Palm OS Windows 95/98 Windows 2000 Windows NT Windows Vista Windows XP Windows 7 Internet Other

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Air Gaging Customizable to Meet Your Application Needs • High performance in tough environments • Easy to use submicron inspection of critical diameters and tapers • More air gage display choices • New materials - high chrome alloys improve performance, shorten deliveries • Available for fast delivery

• A fast, accurate, portable gauge for testing aluminum, brass, copper and steel. • Test a variety of shapes, extrusions, tubing and flat stock. • Models available to test thickness up to one inch.

WEBSTER INSTRUMENT, INC. 11856 Mississippi Avenue Los Angeles, California 90025 EST. 1932

www.webstertesters.com

Tel. 800-394-3541 • Fax 310-478-1365 www.qualitymag.com

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

July 2011 | QUALITY

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✪ View product spec sheets for these companies at www.qualitymag.com/softwareselector

Company/Software Name Retriever Technology Ltd. P.O. Box 3, Tenbury Wells, England, U.K. WR15 8YX 441584781444 A2Z MANAGER 1.16 Easy-FMEA 1.08 Sciemetric Instruments Inc. 360 Terry Fox Dr., Ste. 100, Ottawa, Canada K2K 2E7 (866) 900-7054 Fax: (613) 254-5313 QualityWorX 3.11 -SigmaXL Inc. 920 Yonge St., Ste. 803, Toronto, Canada M4W 3C7 (888) 744-6295; (416) 236-5877 Fax: (416) 352-0037 www.sigmaxl.com DiscoverSim Beta SigmaXL 6.11

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QUALITY | July 2011

4/6/11 10:28 AM

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Company/Software Name -StatPoint Technologies Inc. 560 Broadview Ave., Ste. 201, Warrenton, VA 20186 (800) 232-7828 x350; (540) 428-0084 x350 Fax: (540) 428-0089 [email protected] OR [email protected] www.statpoint.com OR www.statgraphics.com STATBEANS Statistical Java Bean Library STATGRAPHICS Centurion XVI.I MultiLingual Edition STATGRAPHICS Centurion XVI.I Professional Edition STATGRAPHICS Online Statgraphics Sigma Express Steudel & Schultz LLC 313 W. Beltline Hwy., Ste. 184, Madison, WI 53713 (866) 271-3121; (608) 271-3121 Fax: (608) 838-8985 AS9100C Employee Pocket Guide & Training Video AS9100C Teledyne DALSA 700 Technology Park Dr., Billerica, MA 01821 (978) 670-2002 Fax: (978) 670-2010 iNspect Sherlock

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Company/Software Name Thread Check Inc. 390 Oser Ave., Hauppauge, NY 11788 (631) 231-1515; (800) 767-7633 Fax: (631) 231-1625; (800) 767-2034 [email protected] OR [email protected] www.threadcheck.com ThreadTech v2.24 for Windows Transformation Software Inc. 375 Michener Rd., Guelph, Canada N1K 1E8 (519) 822-7648 x22 Fax: (519) 822-2633 [email protected] www.transformationsoftware.com PPAP Creator Step Ahead Software Verisurf Software Inc. 1553 Harmony Circle, Anaheim, CA 92807 (714) 970-1683 Fax: (714) 701-0280 [email protected] OR [email protected] www.verisurf.com Verisurf Analysis x5 Verisurf Build x5 Verisurf Measure x5 Verisurf Reverse x5 Verisurf-X Basic x5

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Spend less time searching for information

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The 2011 QUALITY

SELECTION GUIDES: Software Selector Services Guide Registration/Certiﬁcation Guide Measurement, Test & Inspection Guide • Search by product category or company name • Downloadable product spec sheets • Alpha company listings • Live web & email links • Product photos

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Company/Software Name Vintara 1714 Franklin St., Ste. 100303, Oakland, CA 94612-3409 (925) 386-0435 Fax: (888) 873-8842 Vintara QMS Waypoint Global 6910 N. Shadeland Ave., Ste. 200, Indianapolis, IN 46220-4274 (317) 624-4037 Fax: (866) 571-5482 [email protected] www.waypointglobal.com Powerway Suite V3.50

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NE CMM First Article Inspection Reverse Engineering DCC Full Automation Capability Contract Inspection & Layout Non-Contact Video Inspection 3D Scanning White Light & Laser Scanning 3D CAD Model Based Inspection On-Site Measurement

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Height Gages Accuracy - Innovation - Value Digimar® 816 CLM • Precise measuring results in your production environment

Q-PLUS Labs

• Simple to use - yet high performance functions • Extremely accurate using double scale system

Multi-Sensor Vision Systems 3D Scanners & Software Portable CMMs CMM’s & Accessories Optical Comparators Optical Video Probes Precision Hand Tools Custom Gages Retrofits

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July 2011 | QUALITY

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MANAGEMENT

Money Makes a

Comeback Those in research and development earn an average of $87,585, a decrease of 8.5% compared to last year, while those involved in manufacturing management/operations bring home an average of $87,266, a 6.4% increase from last year. In other areas, manufacturing engineers earn an average of $77,379 and those in quality/product assurance/control average $74,894. Quality professionals in the computer and electronic product manufacturing sector bring home the largest paychecks at an average of $87,806. This is followed by the aerospace product/ parts manufacturing sector, which averages $86,599, a 9.5% increase from the previous year. Those in electrical equipment, appliance and component manufacturing average $84,867, and those in medical equipment and supplies manufacturing average $82,717. Last year quality professionals in navigation, measuring, electromedical and control instruments manufacturing took the top spot as the category with the highest paid workers with an average salary of $94,900, but this year salaries fell 18.1% to $77,750.

Quality professionals are seeing more money line their pockets. BY GILLIAN CAMPBELL, EDITOR

I

t’s been a bumpy road the past few years, but now that the economy has leveled out somewhat and manufacturers are starting to see orders come in on a regular basis, the quality professional is receiving his piece of the proverbial pie. Nearly half of the respondents to the 11th Annual Quality State of the Profession Study received a salary increase and are taking home an annual average pay check of $78,504. Compared to last year, an additional 19% of survey respondents are taking home a bit more this year. Building on those numbers, 63% of respondents anticipate a salary increase of their next performance review. THE BOTTOM LINE The average salary for the year’s respondents of $78,504, is a 6% increase from last year’s average annual salary of $74,028. In last

year’s survey, only 29% of respondents received a salary increase, but this year 48% received an increase. Compared to the 20% who received a pay decrease last year, workers this year fared better—only 6% reported a salary decrease, but for those who received a decrease, the average pay cut was 18%. Quality professionals fortunate enough to receive a raise saw an average increase of 5%. For the 46% of respondents whose salaries stayed the same when compared to the previous year, the most often cited reasons were pay freezes, the economic climate and a decrease in sales and/or profits. Not surprisingly, corporate management takes home the largest paycheck with an annual average salary of $109,324, but this is a 5.1% decrease from the previous year’s annual salary of $115,183.

ANNUAL SALARY COMPARED TO LAST YEAR

SALARY INCREASE FROM LAST YEAR

Decrease: 6% 10% or more

11%

Increase: 48% 5% to 9%

19%

4%

12%

3%

36%

1% to 2%

21%

No Change: 46% 0

5

10

15

20

25

30

35

40

45

50

Percent of Respondents

52

QUALITY | July 2011

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MANAGEMENT AVERAGE HOURS WORKED PER WEEK CHANGE IN NUMBER OF HOURS SPENT AT WORK IN PAST YEAR

66 to 70

1%

61 to 65

1%

Remained the Same - 62% 56 to 60

8%

Increased - 33% 51 to 55

14%

46 to 50

28%

41 to 45

35%

36 to 40

Decreased - 5%

11%

35 or less

1% 0

5

10

15

20

25

30

35

40

Percent of Respondents

LENGTH OF CAREER

LENGTH OF EMPLOYMENT AT CURRENT COMPANY

More than 25 years

More than 25 years

13%

21 to 25

21 to 25

7%

16 to 20 11 to 15 6 to 10 3 to 5

8%

0 to 2 Years

15% 15

11%

3 to 5

22%

10

15%

6 to 10

21%

0 to 2 Years

13%

11 to 15

15%

5

20%

16 to 20

8%

0

30%

20

25

30

3% 0

In general, the larger the company an employee works for, the more he can expect to be paid. Those working for companies with 5,000 or more employees average $103,501 annually, a 3.4% increase from last year. Respondents working for smaller companies seem to have been rewarded for sticking it out through the tough times; they received 14.9% increase in salary for an average of $69,576. The region of the country in which quality professionals work also affects their pay. Workers in the Northeast, Midwest and South saw their salaries increase this year. In past years, workers in the West have garnered the largest paychecks, but this year their salaries decreased 5.8% to an average of $78,043. This year workers in the South received a staggering 16.7% pay

54

QUALITY | July 2011

5

10

15

20

25

30

Percent of Respondents

Percent of Respondents

increase to an average of $84,682, while those in the Southeast and Midwest saw more modest salary gains of 6.2% and 5.3%, respectively. As is the case in many fields, quality workers are rewarded for continuing their educations. Workers completing a certificate program brought home, on average, $59,932. Those with a high school diploma brought home an average of $65,586, an 18.5% increase from last year. That is followed by those with an associate degree was worth $69,098; a bachelor’s degree, $80,109; and a master’s degree, $92,084. Quality professionals with a Ph.D. earn an average salary of $140,444, a 34% increase from last year. The lowest salary reported for a quality professional this year of $12,000 was from a male, working at

a company of less than 50 employees. He works in the Midwest as a quality/ product assurance/control specialist in the computer and electronic manufacturing sector, holds a master’s degree and maintains ASQ certification. On the opposite end of the spectrum, the largest salary reported in this year’s survey of $220,000 is from a male who works at a company of more than 5,000, also in the computer and electronic product manufacturing sector. He works in the Northeast in manufacturing management/operations, has a master’s degree and is a Six Sigma champion. The good news is that 63% of respondents expect an increase in their salary at their next performance review. Another 35% expect no changes in salary compensation and only 1% expects a decrease in salary.

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AVERAGE QUALITY PROFESSIONAL AT A GLANCE » Gross Annual Compensation: $78,504

» Average Hours Worked Per Week: 47

» Average Age: 51

» Average Number of Employees Supervised: 11

» Average Years at Current Company: 12

» Primary Job Function: QA/QC (73%)

» Average Length of Career in Years: 20

» Average Company Size: 4,788 employees

When it comes to annual bonuses, again those at larger companies fared better. Almost 63% of quality professionals at companies with more than 5,000 employees took home a bonus to the tune of $8,815 on average. On the other side of the spectrum, only 39% of quality professionals at companies with less than 50 employees took home bonuses that averaged $1,666. The amount of education also affects the size of the bonus. The average bonus for a quality professional with a high school diploma was $1,724, compared to the average $9,400 bonus for a quality professional with a Ph.D. The largest reported bonus of $60,000 is from a respondent who holds a bachelor’s degree. The dollars and cents on the paycheck is only part of the quality professional’s total compensation package. Ninety-five percent of quality workers are offered health insurance, 93% are offered vacation time; 89% are eligible for 401(k), 85% are offered dental insurance; and 79% are offered life insurance. Tuition reimbursement is available for 60%, and on-the-job training is available for 51%.

Last year 17% of companies were not able to meet quality expectations that exceeded in-house capacity. This year

» Highest Level of Education: Bachelor’s Degree (40%) » Job Satisfaction: Moderate

the number has dropped to 8%. The average quality professional wears a variety of hats. As part of their

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July 2011 | QUALITY

55

MANAGEMENT JOB CONCERNS Management Support

41%

Economic Conditions

38%

Job Security

29%

Keeping Current on Technology

23%

Salary

22%

Sufficient Operating Budget

19%

Keeping Current on Regulations

16%

Outsourcing, Privatization

7%

Company Merger or Acquisition

6% 0

10

20

30

40

60

50

Percent of Respondents

PRIMARY JOB FUNCTION Quality/Product Assurance Control

73%

Corporate Management

7%

Manufacturing Engineering

6%

Manufacturing Management/Operations

6%

Research and Development

5%

Other

2% 0

10

20

30

40

60

50

70

80

Percent of Respondents

PRIMARY PRODUCT MANUFACTURED Aerospace Product/Parts Manufacturing

14%

Fabricated Metal Products Manufacturing

13%

Medical Equipment and Supplies Manufacturing

13%

Miscellaneous Manufacturing

12%

Electrical Equipment, Appliance and Component Manufacturing

8%

Plastics and Rubber Products Manufacturing

8%

Motor Vehicle, Body, Trailers, Parts Manufacturing

7%

Primary Metal Manufacturing

7%

Computer and Electronic Product Manufacturing

6%

Machinery Manufacturing

5%

Other Transportation Manufacturing

3%

Navigation, Measuring, Electro Medical and Control Instruments Manufacturing

2%

Furniture and Fixtures Manufacturing

1% 0

2

4

6

8

10

12

Percent of Respondents

56

QUALITY | July 2011

14

16

18

20

quality-related work activities that are part of their primary responsibilities, most respondents (80%) implement solutions to problems; 72% interface with management; 66% deal with customers; 65% document adherence to formal standards such as ISO; 61% deal with suppliers; 57% supervise day-today operations; 52% work on continuing education/training; and 49% are responsible for implementing quality methodologies, such as Six Sigma and lean manufacturing. In 2009, time constraints and budget cutbacks, both at 59%, topped the list of expected job constraints/barriers in the upcoming year. Time constraints continue to be an issue as cited by 65% of respondents. Last year budget cutbacks were cited as a concern by only 44% of those surveyed, and this year the number has dropped even further to 27%. A growing concern among quality professionals over the years has been the lack of management support. This year it is the second most cited barrier (40%) that will impact quality professionals’ jobs. Other barriers mentioned in this year’s survey include dealing with customers, 39%; dealing with suppliers, 36%; skilled labor shortage, 29%; new and existing standards, 26%; integrating in-process measurement, 25%; and making new technology work and information overload, both at 22%. In addition to the barriers and constraints quality professionals deal with on a regular basis, there are a number of issues which they are concerned about. For the past several years economic conditions have kept respondents awake at night, but this year the top concern is management support (41%). While worries about the economy have decreased 12% during the past year, it is still a top concern among 35% of respondents. Closely related, job security is mentioned by 29% of quality professionals as a concern, a 9% drop from last year, and a 15% drop in the past two years. Edging up the list of concerns is the need to keep current on technology, with 23% citing it as a concern, an 8% increase from a year ago. On the positive side, it appears that companies are committing more resources toward improving quality operations during the next three years.

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AGE 60 and Older

JOB SATISFACTION Not Satisfactory: 8%

18%

50 to 59

Moderately Satisfactory: 56%

44%

40 to 49

Highly Satisfactory: 36%

25%

30 to 39

10%

Up to Age 29

3% 0

5

10

15

20

25

30

35

40

45

50

Percent of Respondents

Fifty percent see their companies as willing to commit to more resources, up from 36% two years ago. Only 7% expect their companies to commit fewer resources to quality, down from 19% two years ago. And 43% expect their company to commit the same resources toward improving quality. On par with previous years, when it comes to embracing new quality technology, 35% of companies are willing to be one of the early leaders, while another 35% will wait until others successfully use it. Another 15% are likely to be the last to embrace new quality technology, and another 15% are willing to be on the leading edge. Given the ups and downs of the manufacturing industry the past several years, it is reassuring to know that the number of quality professionals who are highly satisfied in their jobs remained the same this year at 36%. Again this year 56% find their jobs moderately satisfactory, while 8% are not satisfied with their jobs. While working at a larger company may have its advantages such as larger salaries and bonuses, it is interesting to note that companies with more than 5,000 employees also have the largest number of employees who are not satisfied with their jobs (14.5%). TRAINING The majority of companies (79%) offer their employees opportunities for ongoing training throughout the year. For those who took training, quality methodologies such as Six Sigma were the leader with 35% engaging in the type of training. Thirty-two percent of manufacturers took ISO, FDA and other regulatory standards training,

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AVERAGE SALARY BY REGION

Midwest $73,802 Northeast $82,105

West $78,043

South $84,682

WHAT QUALITY-RELATED ACTIVITIES WERE PART OF YOUR PRIMARY RESPONSIBILITIES DURING THE PAST YEAR? (MULTIPLE RESPONSES ALLOWED) Implement solutions to problems

80%

Interfacing with management

72%

Dealing with customers

66%

Document adherence to formal standards (ISO, etc.)

65%

Dealing with suppliers

61%

Supervise day-to-day operations

57%

Continuing education/training

52%

Implementing quality methodologies (Six Sigma, Lean Mfg., etc.)

49%

Increase productivity/utilization

48%

Research new methods and technologies

46%

Evaluate proposals from suppliers

34%

Prepare/review budgets

30%

Transitions to ISO 9000

16% 0

10

20

30

40

50

60

70

80

90

100

July 2011 | QUALITY

57

Percent of Respondents

MANAGEMENT while 32% participated in management training. While training is an important aspect of many jobs and experts stress the importance on on-going training, 21% of respondents did not partake in any training in the past year. For those who participated in training, educational opportunities have taken many forms including: • Self-study, books, 56% • On-the-job training, 49% • Online seminars/Webcasts, 46% • Off-site seminars, 39% • Trade magazines, 37% • Technical training, 34% • Trade shows, 31% • Association training, 30% • On-site seminars, 28% • Courses at local colleges, 21% • Equipment training, 19% When factoring in gender in regards to the type of training respondents

When it comes to the types of skills quality professionals would like to develop in the next year, men are more likely than women to take time management courses, 39.2% vs. 31.9%. Women, on the other hand, would like to develop project management skills (55.1% vs. 45.7%) and problem solving skills (49.3% vs. 43.6%).

have taken in the past 12 months, more men (14.8%) have taken training in equipment operation/repair than women (6.5%). Men also have taken more training in regards to PC software than women, 24.5% vs. 14.5%. On the flip side, half of the women respondents have taken ISO 9000 training compared to 31.4% of men. More women (70.8%) than men (59.9%) have obtained ASQ certification. Look for quality professionals to continue developing their skills in the next 12 months, particularly in the following areas: • Project management, 42% • Problem-solving, 40% • Time management, 33% • Employee supervision, 17% • Teamwork, 15% • Writing reports and proposals, 15% • Finance and accounting, 13% • Public speaking and presentations, 11%

TYPICAL QUALITY PROFESSIONAL Still a male-dominated industry, the number of females in the quality field dipped slightly this year to 14%. The majority of respondents (73%) works in quality/product assurance/ control and has supervisory responsibility. For the 61% who oversee employees, 43% oversee between two to five employees, while another 21% oversee six to 10 employees and 19% oversee 11 to 25 employees. Many (40%) have received a bachelor’s degree

MOST IMPORTANT JOB ATTRIBUTES

GENDER Female: 14%

Feeling of Accomplishment

Male: 86%

46%

Technical Challenge

34%

Good Relationship with Colleagues

33%

Salary

31%

Job Security

27%

Pleasant Work Environment

23%

Chance to be a Team Leader

7% 0

5

10

15

20

25

30

35

40

45

50

Percent of Respondents

HIGHEST LEVEL OF EDUCATION COMPLETED

CERTIFICATION DESIGNATIONS HELD (MULTIPLE RESPONSES ALLOWED)

Ph.D.: 2% ASQ Certification

Master's Degree: 22%

Six Sigma Green Belt

38%

Six Sigma Black Belt

Certificate Program: 10%

28%

Six Sigma Master Black Belt

6%

Six Sigma Champion

6% 0

10

20

30

40

Percent of Respondents

58

High School: 11%

61%

QUALITY | July 2011

50

60

70

Bachelor's Degree: 40%

Associate Degree: 15%

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DO YOU HAVE SUPERVISORY RESPONSIBILITY?

and hold ASQ certification (61%). Eighty-seven percent of quality professionals are 40 or older, with the largest number of respondents (44%) falling in the 50- to 59-year-old category. The average quality professional has been in the industry 20 years and at his current company for 12 years. Thirty percent of respondents have been involved in quality for more than 25 years and of those, 13% of respondents have been at their current company for more than 25 years. Quality professionals are most likely to work in the Midwest (43%) at a company with less than 500 employees (66%). He likely works between 41 to 50 hours per week, which has remained the same for many (62%) during the past year. The typical quality worker is likely part of a team or committee that sets quality goals for: • New processes, 68% • Productivity, 62% • New product development, 54% • New investments, 39% METHODOLOGY A total of 24,775 active, qualified Quality Magazine direct-request subscribers were selected from the domestic (United States only) circulation with e-mail addresses whose job titles included management, manufacturing engineering, manufacturing/operations, quality/product assurance, engineering/technical, and research and development. These subscribers principle product manufactured includes: furniture and fixtures, rubber and miscellaneous plastic products, primary metal industries, fabricated metal products, nonelectronic machinery, electric and electronic equipment, transportation equipment and instruments and related products. A Web-based survey instrument was designed for the study by the Market Research staff of BNP Media. It was sent via e-mail to subscribers between February 7 to February 15, 2011. As an incentive for response, three respondents had a chance to win a $100 American Express gift card. The survey was returned by 627 people for a response rate of 3%. Q

IF YES, HOW MANY PEOPLE DO YOU SUPERVISE?

Yes: 61%

No: 39%

More than 50 people

2%

26 to 50

6%

11 to 25

19%

6 to 10

21%

2 to 5

43%

1 person

8% 0

10 20 30 40 Percent of Respondents

50

OPERATION OF COMPANY (MULTIPLE RESPONSES ALLOWED) Original Equipment Supplier

54%

Components, Parts Manufacturer

45%

Job Shop

21% 0

10

20 30 40 Percent of Respondents

50

60

ANNUAL GROSS COMPENSATION - SALARY ONLY $100,000 or more

20%

$95,000 to $99,999

3%

$90,000 to $94,999

6%

$85,000 to $89,999

7%

$80,000 to $84,999

9%

$75,000 to $79,999

8%

$70,000 to $74,999

9%

$65,000 to $69,999

8%

$60,000 to $64,999

6%

$55,000 to $59,999

4%

$50,000 to $54,999

6%

$45,000 to $49,999

4%

$40,000 to $44,999

4%

$35,000 to $39,999

2%

$30,000 to $34,999

2%

$25,000 to $29,999

1%

Less than $25,000

<1% 0

2

4

6

8

10

12

14

16

18

20

Percent of Respondents

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July 2011 | QUALITY

59

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CASE STUDY Instructions and images are added to programs with Calypso metrology software. Source: Carl Zeiss Industrial Metrology

QUALITY MEASUREMENT FOR THE

AUTOMOTIVE MARKET Zeiss technology allows company to be measurement consultants for its customers and improve customer satisfaction.

A

finishing equipment as well as CMMs s end customers demand more and vision systems, the company is efficient vehicles, automobile well equipped to handle orders of producers also require more adept varying size and complexity. parts from engine component manuBack in 2002, when Camcraft facturers. Camcraft Inc. (Hanover noticed its customers’ target tolerPark, IL) knows this first hand and ances for parts getting tighter, it has been relying on coordinate mearealized it needed more precise and suring machines (CMMs) from Carl efficient quality inspection equipZeiss (Maple Grove, MN) ment. In addition, it to drive it to better cusBENEFITS noticed CMMs were tomer satisfaction. » Previous manual inspection becoming more prevaCamcraft specialmethods such as calipers lent in its industry and izes in hydraulic and and hand gages could take it wanted to be current flow components used hours to measure a part; with the latest techin the automotive and those parts can now be nologies. Its measureoff-road vehicle markets. measured in 5 minutes on ment equipment at that With a manufacturing the Contura. time included v-blocks, facility of more than » Target tolerance capabilconcentricity gages, 112,000-square-feet and ity went from ± two thoudial bore indicators, state-of-the-art equipsandths of an inch before hand gages and caliment, including Hydrothe CMMs down to ± two pers, which could take mat computer numerical ten thousandths of an inch and tighter. hours to measure a part control (CNC) machines, and produced varied Schütte and Euroturn » For Camcraft, the best results from operator multispindle automatic factors of having Carl Zeiss to operator. It wanted screw machines, CNC systems are confidence an inspection machine in-feed, cylindrical and in accuracy, flexibility and reliability. that could offer stanID grinders, micron bore

62

QUALITY | July 2011

dardized inspection programs that various operators could use to measure parts easily and efficiently with consistent and accurate results. After reviewing its customers’ needs and researching different CMM systems, Camcraft decided that a Zeiss CMM was the best product for its needs. In 2002 it purchased a Contura 7/10/6 because the measuring volume was the right size for its parts, it could reach their targeted geometric dimensioning and tolerancing (GD&T) tolerances of two ten thousandths of an inch and tighter, and they liked the machine’s features and versatility. Camcraft chose the Vast XT sensor for its fast scanning speed to gather more data points to get better information, and its integrated sensor change rack provides it with versatility for maximum reproducibility without recalibration. The Calypso metrology software is easy to use and allows Camcraft to standardize programs for use by multiple operators. After its success with the first Contura, Camcraft purchased another and two Contura G2s in the following three years. In addition to these CMMs, it also purchased two Rondcom and two Surfcom systems from Carl Zeiss for surface and form measurements. INSIDE THE LAB Camcraft has four temperaturecontrolled inspection labs on their production floor. Each lab is equipped with a Contura and either a Rondcom or a Surfcom. One lab is dedicated to incoming and outgoing quality inspection, the next is dedicated to custom parts for a few specific customers and the remaining two labs are used for standard part inspection. Many parts going out to a third party for processes, such as heat treatment or thermal deburring, need to have their measurements verified with a CMM before and after these processes. Typical parts for Camcraft are aluminum or steel, about 1-inch long and a half an inch in diameter, but it also measures parts that are about 50 times

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A Contura measures intake/exhaust end pieces used on overhead camshafts for V8 engines. Source: Carl Zeiss Industrial Metrology

larger such as the intake/exhaust end pieces used on overhead camshafts for V8 engines; this is one example of the CMM’s versatility to measure different part sizes. A typical part is first blanked out, then secondary operations are performed such as cross holes or slots, some parts could then be sent out for heat treatment by a third party, and finally precision bore sizing and grinding. Operators bring their parts into the labs at the required production stages for quality inspection on a Zeiss machine. Approximately 50 different parts per CMM are measured multiple times per shift. The ease of use and the ability to standardize measurement programs with Calypso software have been great benefits for Camcraft. “Very little training is required for our operators to use these programs,” states Mike Lee, quality technicianprogrammable metrology at Camcraft. “This is important because new employees are often measuring on these systems within their first week. Our CMM training procedure consists of talking them through the process, walking them through the first few measurements and then they are ready to measure with our standardized programs.” The ability to add images and instructions to different stages of inspection runs,

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Form measurement is done on a Rondcom 60A. Source: Carl Zeiss Industrial Metrology

coupled with QC-Calc SPC to chart and report measurement data, has given Camcraft even more confidence to trust their results. Reduced inspection times and improved accuracy have been the most significant quantifiable results since purchasing the CMMs. Previous inspection methods such as calipers and hand gages were manual and could take hours to measure a part that could be measured on the Contura in five minutes. Target tolerance capability went from + two thousandths of an inch before the CMMs down to + two ten thousandths of an inch and tighter. “The surface and form measurement machines from Carl Zeiss have been a lifesaver for our circular and cylindrical measurements,” remarks Lee. “Our Rondcom 60A is an exacting machine with target tolerances of 0.00004 inch cylindricity.” The Rondcom 60A has a Z axis measuring height of 500 millimeters and a maximum load of 60 kilograms. Their Surfcom 5000DX is used for contour and surface measurements in their inspection lab that is dedicated to special customer projects and highend applications. This DX version of Surfcom features a wide-range laser interferometer probe with an integrated air isolation system and ergonomic console cabinet.

For Camcraft, the best factors of having Carl Zeiss systems are confidence in accuracy, flexibility and reliability. “The Contura can switch from measuring a square part to a round part without requiring a probe change. You can customize probe sets and take a lot of the thought out of programming,” says Lee. “The reliability of all the machines and the service really make Carl Zeiss stand out in our eyes. With the help of applications support and the regional service technicians, we can quickly get assistance with any programming questions or calibrations. “Of course having the capability of saving time and money in your production processes is a huge achievement, but being able to be a resource for your customers who are considering CMM investment is very gratifying and helps us build closer relationships,” states Lee. “We’re both working together with a common goal of strengthening our workplace for everyone. The knowledge we have gained from our experience with Zeiss technology has allowed us to be measurement consultants for our customers which is a key to our success with customer satisfaction.” Carl Zeiss Industrial Metrology (800) 327-9735 www.zeiss.com/metrology

July 2011 | QUALITY

63

CASE STUDY The NVision handheld scanner is a portable scanning device capable of capturing 3-D geometry. Source: NVision Inc.

SCANNING TO FIT A handheld laser scanner is being used to guarantee that aircraft exterior parts are placed correctly the first time.

N

“The handheld laser scanner is a Vision’s (Coppell, TX) handperfect fit for this application because held laser scanner is being used its ability to move freely around a part by Lockheed Martin engineers at its makes it possible to reverse engineer Missiles and Fire Control business virtually any size or shape of part,” says (Orlando, FL) to ensure the fit of accesSteve Kersen, president of NVision. sories to aircraft exteriors and interiors The scanner is attached are positioned perfectly the to a mechanical arm first time. BENEFITS which moves about The NVision handheld » NVision’s handheld scanthe object, freeing scanner is a portable ner has helped Lockheed the operator to capscanning device capable Martin engineers accurately ture data rapidly and of capturing 3-D geommeasure millions of points. with a high degree of etry. NVision’s handheld » The handheld laser scanner resolution. An optional scanner has helped Lockcan reverse engineer virtually tripod provides comheed Martin engineers any size or shape of part. plete portability in the accurately measure mil» Laser scanning provides field. Intuitive software lions of points by simply accurate measurements of allows full model editmoving it over an airparts ranging in scale from ing, polygon reduction craft’s surface, enabling the entire exterior of a comand data output to all perfect fits on first protomercial helicopter down to standard 3-D packages. type iterations. very small components.

64

QUALITY | July 2011

ACCURATE MEASUREMENT “An important advantage of laser scanning is that it provides accurate measurements of parts ranging in scale from the entire exterior of a commercial helicopter down to very small components,” says Stephen Rocca, manager of Mechanical Laboratories at Lockheed Martin Missiles and Fire Control. “Getting the fit correct the first time provides significant time and cost savings. Laser scanning also has improved the accuracy of the fluid dynamic models that we use to predict the effect of the accessories on flight performance, providing a safety advantage.” In building aircraft accessories, it is critical to determine the exact geometry of the aircraft which normally cannot be obtained from computer-aided design (CAD) models because the exact configuration varies from aircraft to aircraft. For example, aircraft interiors are populated with cables and hydraulic lines that often do not show up or show up in a different position in the CAD model. In the past, conventional measuring instruments were used to physically measure the aircraft. For example, technicians would measure the body exterior, rotor, skids, windows and doors of a commercial helicopter. This was a tedious process because an individual measurement had to be taken for each point. There was never enough time to take enough points to fully define the geometry so technicians frequently had to take a best guess as to the exact surface contours. The result was that the prototype often had to be reworked to get it to fit the exterior. The inherent inaccuracies of the manual measurement methods used in the past meant that three or four prototype iterations were typically required to obtain a good match to the aircraft. After NVision demonstrated the ability to obtain high levels of accuracy in laser scanning, Lockheed Martin purchased an NVision handheld scanner for a production site in Alabama, and later, a second scanner, for its Orlando, FL, manufacturing facility. NVision Inc. (972) 393-8000 www.nvision3d.com

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QUALITY

PRODUCTS THE LATEST PRODUCTS TO HELP YOU IMPROVE YOUR MANUFACTURING PROCESS

NONCONTACT SHAFT MEASURING SYSTEM The opticline CA614 noncontact shaft measuring system is designed for submicron measurement of all contour features on complex shaft-type parts up to 600 millimeters in length and 140 millimeters in diameter. The stroke is driven by a motorized tailstock, which is positionable over the full holding range. It is designed for automotive and aerospace applications, including carrier shafts in aircraft engines, drive parts in helicopters and various rotor parts. HOMMEL-ETAMIC (810) 229-2299 WWW.HOMMEL-ETAMIC.COM

HD CAMERA

METRONOR

Aven’s HD microscopy camera has built-in calibration software. It is a 1.3-megapixel color inspection camera and it connects directly to a monitor via a VGA cable. It records linear, circular or angular measurements in millimeters or inches, as well as a radius or between parallel lines. Pointand-click measurement data and images can be saved on a built-in SD card. The screen pointer, controlled via a PS2 mouse attachment, can be set as a fullscreen crosshair or small center crosshair.

(815) 381-0920

AVEN INC.

WWW.METRONOR.COM

(248) 258-5982

VIRTUAL ARM SOLOlite is a virtual arm that applies Metronor single-camera technology to provide a lightweight, carbon fiber handheld probe. A camera observes the probe and determines the probe’s position and orientation. SOLOlite handles measurement volumes of up to 11 cubic meters, with no mechanical moving parts.

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TRACKING SOFTWARE MODULE

MULTISENSOR CMM SOFTWARE

The VXtrack dynamic tracking software module is teamed with Creaform’s C-Track dual-camera optical sensor to measure positions and orientations in space. Combined with the HandyProbe arm-free portable coordinate measuring machine (CMM), VXtrack is a portable 3-D measurement system that handles probing inspection and dynamic measurement. The VXtrack module’s applications include robot calibration and guidance, monitoring of complex assembly processes, real-time compensation of machining tool-generated errors and monitoring of deformations during testing.

Camio7 is multisensor coordinate measuring machine (CMM) software with recent Microsoft Windows upgrades. This serves as the central location where all software functions are logically grouped into tabbed sections, containing all required operations. The software interface allows both feature related measurement and reporting to be defined together.

CREAFORM | (302) 444-6696 | WWW.CREAFORM3D.COM

WWW.NIKONMETROLOGY.COM

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QUALITY | July 2011

NIKON METROLOGY INC. (810) 220-4314

www.qualitymag.com

PRODUCTS

DOPPLER DISPLACEMENT METER

INSPECTION GAGE

The MarForm MMQ 200 Formtester has a new option package that provides the measurement of surface finish parameters according to ISO, ASME and JIS standards. With the combined hardware/software MMQ 200 Surface Finish option, it has a reduced setup and measurement cycle time and reduced cost.

The LDS1000HS is a high performance laser doppler displacement meter with laser frequency stability of 0.01 parts per minute, positioning accuracy of 0.1 parts per minute and high signal-tonoise ratio. This system is designed for positioning feedback or calibration of such ultra-precision stages. The laser frequency stability is better than 0.01 parts per minute and the resolution is 1 nanometer. The major features are: high resolution and high accuracy, noncontact and no need for periodic calibration.

The Heidenhain ND 2100G Gage-Chek will handle gaging and inspection tasks from pass/fail detection to complex logic statements communicating to a PLC. They can be configured for basic or advanced operations where inputs can be assigned and combined as desired, along with mathematical, trigonometric or statistical formulas. Rapid acquisition of measurement data can monitor dynamic events such as the eccentricity of a rotating shaft.

MAHR FEDERAL INC.

OPTODYNE INC.

WWW.HEIDENHAIN.US

(800) 343-2050

(310) 635-7481

WWW.MAHR.COM

WWW.OPTODYNE-USA.COM

FORMTESTER

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QUALITY | July 2011

HEIDENHAIN (847) 490-1191

www.qualitymag.com

LASER SCANNER

4-PORT GAGE MULTIPLEXERS

ABSOLUTE ENCODER

The 4-Port Gage multiplexers connect multiple gages to a PC. Both models in the line, the 7612 and 7613, support USB 2.0, RS 232 and USB keyboard optional outputs. Each model has a power-saving mode, as well as foot switch input, LED status light on each input, host command operation and set up. The 7612 Gage MUX does not require a software wedge or other intermediary software for operation. A user’s PC “sees” the connection with the 7612 multiplexer as a keyboard.

The Resolute absolute encoder is now available with Fanuc serial communications in linear encoder formats, which have submicron accuracy and resolutions to 1 nanometer. The Resolute determines absolute position immediately upon switch-on, thus eliminating the need for battery back-up or reference returns. Images are captured, analyzed and interpolated to resolutions as fine as 1 nanometer at speeds up to 100 meters per second.

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The Skiron laser scanner is a compact scanning attachment designed for MicroScribe 6 degree of freedom (6DoF) digitizers, which are meant to enable operators to more rapidly and accurately digitize physical forms. Revware’s MicroScribe digitizer is a data collection tool used to gather specific measurements for concept-to-product engineering. When used with the Skiron Laser scanner, data collection can help produce a high-quality scan in minutes. It is suitable for all three-dimensional application needs within engineering, medical, science, inspection, automotive and multimedia industries. KREON TECHNOLOGIES (434) 946-9125 WWW.KREON3D.COM

EXCEL SPC CHARTING

The zCAT is a portable direct computer control coordinate measuring machine (DCC CMM) designed to support production operations such as precision machining and tool making. It is battery powered and targeted at shop floor measurement. It is an alternative to portable arms, on-the-machine touch probing and other stationary CMMs that require electrical and pneumatic connections.

QI Macros wizards can analyze an operator’s data and select the correct analysis to perform. Included is a Chart Wizard that analyzes data and chooses the right control chart from seven possible charts. The PivotTable Wizard will take up to four columns of tabular data and summarize them using Excel’s PivotTable function. The Statistics Wizard will analyze data and choose the right hypothesis tests to run. The Statistics Wizard will figure out the correct analysis to run and will interpret the results for the user.

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CAD-Based Inspection Using Contact Measurement August 9, 2011 | 2pm EDT Over the years, CAD-based inspection has become more prominent in the manufacturing world. Using contact measurement technology can help you achieve your CAD inspection goals. This webinar will discuss how CAD became integrated into the manufacturing process (CAM) and the inspection process using MBD (Model Based Deﬁnition). You will also see a demonstration of how portable contact measurement technology allows you to easily align to a CAD model, and what you can do once you are aligned (checking proﬁles, prismatic feature location and size, and more). What you will learn in this webinar: • Types of CAD models • How CAD became integrated into manufacturing and inspection processes • Advantages of using MBD (Model Based Deﬁnition) • The use of contact measurement (aligning to CAD, checking proﬁles, checking features, etc)

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ADVERTISING INDEX ADVERTISER

PAGE

Accelper Consulting

24

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IBC

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Assetsmart

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Automated Precision Inc.

11

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Bal-Tec Division, Micro Surface Engr. Inc.

14

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BSI

48

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Cebos

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Creaform

29

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CSC Force Measurement Inc.

24

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Darrell Dal Pozzo

Cybermetrics Corp.

BC

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DataNet Quality Systems

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DNV Business Assurance

12

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Gage Assembly

32

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Gagemaker Inc.

21

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Hemco Corp.

49

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REGIONAL MARKETING NEW ENGLAND AND MID-ATLANTIC

5

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Imada

29

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InﬁnityQS International

33

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Phone: (856) 358-4800

Hommel-Etamic America

Intelex

16, 69

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1, 15, 47, 51

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Mark 10 Corp.

7

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Micro-Vu Corp.

55

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MicroRidge Systems Inc.

21

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Minitab Inc.

26

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Mitutoyo America Corp.

IFC

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NCSL International

65

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Olympus NDT

13

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Origin Technologies Corp.

10

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FAX: (856) 358-0900

Mahr Federal Inc.

[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]

PQ Systems

14

www.sqcpack.com

MIDWEST, SOUTHWEST,

Q-Plus Labs

51

www.qpluslabs.com

WEST AND NORTHWEST

R.L. Schmitt Co. Inc.

25

www.rlschmitt.com

Buck Bicek 5820 Middaugh Ave.

S-T Industries Inc.

9

www.stindustries.com

10

www.qmi-saiglobal.com

3

www.starrett.com

UBM Canon

67

www.qualityexpo.com

Verisurf

17

www.verisurf.com

Webster Instrument Inc.

47

www.webstertesters.com

Western Gage Corp.

32

www.westerngage.com

Yxlon International

23

www.yxlon.com

SAI Global

Downers Grove, IL 60516 Phone: (630) 971-0904 FAX: (248) 502-1086 [email protected]

INSIDE SALES INSIDE SALES MANAGER

Starrett Co., The L.S.

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

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

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QUALITY | July 2011

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

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WHAT MACHINE VISION SOLUTION IS RIGHT FOR YOU? P. 12VS

See in color Matrox Iris GT smart camera brings color to your vision Sometimes, color is all you have to identify a part or product and confirm its quality. Matrox Iris GT smart cameras now have the ability to let you pick out the slightest color variations, while Matrox Design Assistant flowchartbased integrated development environment lets you set up your color vision application with ease. Download our white paper! “Color Machine Vision”: www.matroximaging.com/colorwp

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VISION & SENSORS

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

July 2011 12VS

DEPARTMENTS 4VS Editor’s Note

Choices 6VS Industry News 16VS Case Study

Putting It All on the Line 24VS Products IBCVS Advertising Index IN THE NEXT ISSUE Line-Scan Cameras Universal Machine Vision Software Advances in Vision Sensing LEDs 3-D IMAGING

8VS

ABOUT THE COVER

3-D IMAGING FOR ON-LINE PRODUCT AND PROCESS CONTROL

July 2011

www.visionsensorsmag.com

The selection of an appropriate 3-D technique depends on the feature(s) to be quantitatively determined. MACHINE VISION 101

12VS WHAT MACHINE VISION SOLUTION IS RIGHT FOR YOU WHAT MACHINE VISION SOLUTION IS RIGHT FOR YOU? P. 12VS

By following this easy, three-step process, your selection of the right vision solution for your needs will be better assured.

A Technician uses the Edge arm with a Laser Line Probe attachment to provide non-contact, 3D imaging to reverse engineer a part. Source: Faro

VISIT VISION & SENSORS ONLINE AT

www.visionsensorsmag.com Digital Cameras Enable Advanced Research in Microscale Fluid Behavior

2VS

VISION & SENSORS | July 2011

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Teledyne DALSA image technology is extremely versatile and easy to deploy. We have an image solution ready to meet your requirements, like the BOA IDR image-based ID reader designed for part recognition, tracking and verification applications. BOA IDR combines 1D and 2D reader tools with character (OCR) and pattern recognition capabilities to identify or verify all required product markings.

Get more vision. Download our whitepaper: BOA assists in Pharmaceutical and Medical Packaging www.teledynedalsa.com/july/vs2011 *DALSA is now Teledyne DALSA.

VISION & SENSORS

FROM THE EDITOR

Choices Choices. We all make them, everyday. From the clothes we wear to the business deals we make. Some are routine and are given little thought. Others are life-changing and we pour over every detail and sweat every possible outcome. Regardless of how important, and whether we are aware of it or not, these choices are governed by circumstance, experience and even emotion. About ten years ago, the entire country was embedded in the controversy of a choice. And I am sure we all remember it, because it was a particularly important choice—who would be the next President of the United States. In 2000, the United States presidential election was one of the closest and most controversial presidential elections in history. A month of recounts and court challenges followed culminated in a Supreme Court case. Following the court’s 5-4 decision, George W. Bush was declared the winner over Vice President Al Gore by 537 votes in the state of Florida. This was the 16th time in history that a candidate

won the Electoral College vote without receiving the majority of the popular vote. While the subject was debated by the highest court in the land, it also was the topic of water-cooler discussions, talk-show and news segments, and eventually a couple of movies. Some of the more memorable aspects of the controversy included the notorious Palm Beach butterfly ballot, which produced an unexpectedly large number of votes for third-party candidate Patrick Buchanan; the purge of some 50,000 alleged felons from the Florida voting rolls that included many voters who were

eligible to vote under Florida law; not to mention the hanging chad. There has also been much speculation on what might have happened if there had been recounts under different rules. A consortium of newspapers did an investigation that flushed out a number of scenarios, even going as far as to say that Bush still would have won under the recounts that Gore had proposed. It is not really a surprise that the situation bred such emotion, speculation and interest. Again, not only because of the impact on the highest echelons of government, but also because of the importance of choice. The idea of choice permeates through our government and our lives. Choice surrounds important philosophies on ethics and behavior and is an important tenant of capitalism itself. Existentialists have commented that even when we choose not to make a choice, we are making a choice. So join the likes of Kierkegaard, Sartre and Getty Lee and read about choosing the right equipment for the job in this month’s feature articles, “What Machine Vision Solution is Right for You,” by Kevin Shayne and Dr. Norman N. Axelrod’s “3-D Imaging for On-Line Product and Process Control.” Enjoy and thanks for reading!

Darryl Seland, Editor in Chief

Vision & Sensors Editorial Advisory Board David Dechow Aptura Machine Vision Solutions

4VS

VISION & SENSORS | July 2011

Ned Lecky Lecky Integration

Perry West Automated Vision Systems Inc.

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NEW

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VISION & SENSORS

NEWS

Lecky Integration Adds Two to Staff LITTLE FALLS, NY— Lecky Integration, a technical consultant company that partners with government agencies, system integrators, OEMs, Fortune 500 companies, and entrepreneurial start-ups, has doubled in size since the start of the new year. Recent hires include: • Josh Johnson, a graduate of William and Mary with a degree in Computer Science and a graduate of Full Sail University, who also holds a bachelor’s degree in Game Development. • Dustin Holtz, a graduate of Full Sail University, with a bachelor’s degree in Game Development. Holtz and Johnson join Keith Morgado, also a software developer, and Michael Vittiglio, who was recently promoted to manager of software development in order to help effectively manage company growth and client deliverables.

MACHINE VISION AND VISION GUIDED ROBOTICS MARKET TO REACH $15.3B DALLAS—According to a new market research report, “Global Machine Vision and Vision Guided Robotics Market (2010 - 2015),” published by MarketsandMarkets, the total global machine vision system and component market is expected to be worth $15.3 billion by 2015, out of which the camera and smart camera will account for nearly 27.3% of the total revenues. The global market is expected to record a CAGR of 9.3% from 2010 to 2015. The machine vision system and component market has advanced very fast to meet the growing demand for traditional and non-traditional applications areas. Advancement in processing capabilities has made the machine vision systems more powerful; coupled with the development of smart camera and new interfaces. These advancements have also increased processing power, reduced cost and operational complexities, thereby increasing the scope of machine vision technology for a wider application. The global machine vision system and components market is estimated to reach

6VS

$9,830.4 million in 2010; growing at an estimated compound annual growth rate (CAGR) of 9.3% from 2010 to 2015. Among all the market segments, the optics, lighting and frame grabbers commanded the largest share in terms of revenues in 2010, while camera and smart camera came second in terms of revenues. However, camera and smart camera is the fastest growing market, growing at a CAGR of 10.2% from 2010 to 2015, due to the higher demand for smart camera because of its lower cost of the system and easy to install and use. Processor, software, and hardware market is expected to reach $3,641.6 million in 2015 with an estimated CAGR of 8.8% from 2010 to 2015. At present, Asia Paciﬁc region dominates the global machine vision system and component market, which is also the fastest growing region, at a double digit CAGR of 11.1% from 2010 to 2015 and this trend is expected to continue in the forecasted period as well; followed by North American region, the second largest market for machine vision, which occupied market share of 32.2% of the overall market in 2010. However, ROW was the

VISION & SENSORS | July 2011

smallest market for machine vision system and components in 2010.

NATIONAL INSTRUMENTS ANNOUNCES 2011 GREEN ENGINEERING GRANT PROGRAM AUSTIN, TX—National Instruments (NI) has announced its 2011 Green Engineering Grant program, a worldwide competitive program that fosters rapid design, prototyping and commercialization of promising new renewable energy, energy efﬁciency and smart grid systems. Through the program, NI will donate up to $25,000 USD equivalent in NI LabVIEW graphical system design software tools and training to eligible startups to help advance clean energy development in applications such as solar, wind and biofuel technology. The 2011 program has a special focus on technologies that improve the smart grid and provide the foundation for a clean energy future. “With only three employees, we work hard to develop clean energy solutions for people in developing nations,” says Matt Bennett, vice president of research and development for Windlift, a startup company that develops mobile airborne wind energy systems, including onboard energy storage for mobile microgrids in post-conﬂ ict reconstruction and disaster relief. “The NI Green Engineering Grant gave us the tools to facilitate rapid development of our technology, helping us to progress from concept to prototype in just eight months. Also, the same hardware and software will carry through the entire technology development process, providing a smooth transition when we are ready to enter production.” To date, the NI Green Engineering Grant program has delivered NI software and training to more than 40 startups and small companies working on a variety of revolutionary renewable energy applications. The following examples demonstrate how past grant recipients are using NI tools in their renewable energy solutions:

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• Powering remote villages with portable airborne wind technology • Producing quality transportation fuels from inedible plants • Generating electricity by harnessing ocean thermal energy Because smart grid technology is a foundation for renewable energy innovation, the company will host, on April 19–21, an interactive Earth Week webcast series about smart grid technologies and the 2011 Green Engineering Grant program. The three-part series examines the rapidly changing landscape of clean energy, smart grid and energy storage technologies. It also features presentations from past grant recipients and other technical demonstrations that show how NI technology can help engineers develop and speed the adoption of renewable energy systems. Readers can register for the webcast and learn more about the 2011 NI Green Engineering Grant program by visiting http://www.ni.com/ greengrant.

AUGUSTA TECHNOLOGIE ACQUIRES LMI TECHNOLOGIES VANCOUVER, B.C., CANADA – LMI Technologies, a 3-D laser measurement sensors for industrial measurement and control applications company, has sold 100% of its shares to join Augusta Technologie AG – a publicly listed German sensor and vision technology company. As a result of this acquisition, LMI will become part of a larger worldwide company in the ﬁeld of digital imaging technologies. Augusta is located in Munich, Germany, and focuses on two market segments: sensors and vision. “LMI is a perfect ﬁt to our vision activities and will give us access to the rapidly growing 3-D market,” says Amnon Harman, CEO of AUGUSTA Technologie AG. “Combining LMI’s strength in 3-D with our leading market position in digital machine vision cameras will offer multiple beneﬁts and a much broader

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product offering for the combined customer base worldwide.” Augusta’s mission is to further increase its presence in existing and new growth markets – regional and product-related – within the vision industry. LMI’s innovative technology and culture offers entry into the growing 3-D market and further regional expansion, especially into North America.

ACOUSTICEYE WINS TOP HONORS AT MAINTENANCE XIII INTERNATIONAL CONGRESS LEUSDEN, THE NETHERLANDS—AcousticEye’s Daniel Bobrow won the ﬁrst-place award for Engineering Maintenance at the Maintenance XIII International Congress, held April 6-8 in Bogota, Colombia. A jury awarded the top honors to Bobrow for his paper, Implementation of Acoustic Pulse Reﬂectometry (APR) to Quality Control of Heat Exchanger Cleaning. Fifteen speakers from Cuba, Ecuador, United States, Israel, Peru, Venezuela, Netherlands and Colombia shared their experiences in the ﬁeld of maintenance to Congress attendees. The top three papers were awarded prizes. Daniel Bobrow won a trip to the Congress of the Brazilian Association of Maintenance, to be held in September 2011.

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July 2011 | VISION & SENSORS

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3-D IMAGING

3-D Imaging for On-Line Product and Process Control THE SELECTION OF AN APPROPRIATE 3-D TECHNIQUE DEPENDS ON THE FEATURE(S) TO BE QUANTITATIVELY DETERMINED. Dr. Norman N. Axelrod

and remote/battlefield surgery), and laser-guided weapons for ranging, guidance and targeting. As will be evident from the examples following, the selection of an appropriate technique depends on the feature(s) to be quantitatively determined—the x-y-z-resolutions/imagedistances/optical-field required, time per individual inspection and special useful characteristics of the object. Structured lighting, special optical techniques and signal-processing can provide significant improvement advantages in these areas as well as in speed and reliability. Basic 3-D imaging techniques include: • triangulation • time-of-flight/range imaging • microscopy • coherent illumination (including interferometry, holography and tomography).

Illumination techniques used in 3-D imaging using white light and laser-generated lines of light incident at different angles. The rectangles at the conveyor show the areas in the object that are imaged onto different areas on the CMOS sensor in the camera. The four dashed lines from the camera display the field of view on the conveyor belt. (Photo courtesy of Sick)

In this article, 3-D imaging is considered primarily in the context of on-line product and process control. It can obtain data on three dimensional objects for 3-D dimensional gauging, defect detection—including depth and height of defects—part recognition, and structural and material integrity. Applications continue to expand, including confirming the integrity of complex structures, such as engines and integrated cir-

tech tips In triangulation, there are many geometrical and optical variations to improve different features of interest.

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cuits, determining the presence of required components and features, and robot-controlled recognition for pick-and-place operations. 3-D techniques are also used in high-volume consumer products, medical diagnostics (ultrasound

The seemingly relentless advances in electronics (Moore’s Law) have resulted in corresponding improvements in time-of-flight optical imaging.

VISION & SENSORS | July 2011

Special optical techniques and signal processing can provide significant improvement advantages in these areas, as well as in speed and reliability. Variations in illumination techniques, such as structured laser light (lines, line arrays and dot arrays of laser light), are used in different imaging techniques. In Figure 1, different light source geometries are shown. The top three arrows point to three illumination sources. The top left arrow is towards a white-light source that illuminates a broad area on the conveyor belt. The top middle arrow is for a laser that projects a plane of light that produces a line of light at the conveyor for a 3-D measurement of surface height. The top right arrow shows another laser source, incident at a different angle, for pro-

One key to the confocal microscopy approach is the use of spatial filtering to eliminate out-of-focus light or glare in specimens that are thicker than the plane of focus.

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viding scattered light from the tablets that can be used for presence/ absence detection; the surface height sensor can also be used for presence/ absence detection. Different signal-processing techniques are applied to different probes. In time-of-flight imaging, direct time delay can be used. Parallel measurement of the phase and amplitude of an RF modulated illuminating beam is done on some commercially available products. And there are variations within the variations Although 3-D imaging has been applied using optics, ultra-sound, radar and other probes, we shall emphasize optical applications, but include atomic force microscopy. However, the basic physical concepts—which depend on geometry, wavelengths, frequency, timing—are applicable to non-optical techniques. For brevity, coherent optical will not be discussed.

BASIC TECHNIQUES 1. Triangulation Triangulation is used to detect the displacement in the apparent position of a narrow laser beam or line of light incident onto a surface. Triangulation has been used to measure small displacements and the presence of objects, as well as variations in feature dimensions. This is generally referred to as triangulation, since, for a simple system with a narrow laser beam, the three points (e.g. emitting light source on a bar, the point of incidence of small diameter light beam on the object and the photo-sensor along the bar that is used to image the narrow light beam at the object) form a triangle. To measure a 3-D profile, a laser is mounted to project a laser line onto an object at an angle, again, as shown in Figure 1. The camera, which views the line from a different angle, sees a curve that is generated by the changes in surface height. The camera would see a straight line if the surface were flat. In triangulation, as with most of the 3-D imaging & gauging

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techniques, there are many geometrical and optical variations to improve different features of interest. Special characteristics of the objects should be used when possible to improve resolution, sensitivity and reliability. The CMOS area sensor in the camera can provide 3-D gauging. Multifunctional operation is enabled with the CMOS sensor. Different sections of the sensor are software configured, with appropriate lighting, to detect different characteristics such as surface reflection, different wavelengths, laser scatter, as illustrated, again, in Figure 1. Measurements are acquired in a line-scan manner. The three rectangular areas in Figure 1 illustrate how different functions in the image are mapped onto different areas imaged onto the CMOS sensor of the camera. The bottom, left, narrow rectangle shows the grayscale in the image area in the field of view that is mapped onto the CMOS sensor. The broad area rectangle shows where the 3-D area is mapped onto the camera CMOS sensor. The next, bottom, thin rectangle area shows from where the scattered light is imaged onto the CMOS sensor area. The field of view of the camera is shown by the four dashed lines from the camera. In the camera, different areas on the sensor can be assigned to different image components by software. The software can be configured to provide several measurements at the same time, including 3-D provile, laser scatter, color and monochrome. As with other vendors, it provides calibration tools. The 3-D was introduced in late 2010. Figure 2 is an example of another triangulation system. The basic geometry is as described above. It uses laser light to illuminate and then uses a series of detectors to sense the imaged area. This could be a simple triangulation system as described above using a narrow beam of light.

However, it uses the laser light to form an interference (fringe) pattern that illuminates the samples. With this structured lighting, the triangulation is said to provide depth z-resolution down to 30 microns (or 1.2 mils) with lateral resolution down to 200 microns. Other 3-D vision uses geometric pattern matching against stored images to provide real-time, threedimensional position information to work with a variety of stacked or tilted parts. It applies multiple sets of stored two-dimensional images and uses geometric pattern matching tools from its integrated 3-D-Locate software to determine an object’s 3-D orientation. Single or multiple cameras can be used for different resolutions. Calibration tools provide the necessary corrections for optical distortion and camera position. It is said to tolerate non-uniform lighting and even partly covered parts. This applies geometric pattern matching against stored images to provide real-time, 3-D position information to work with a variety of stacked or tilted parts. 3-D imaging is also used to play various games without using any hand-held devices. I steered a boat, on white water river, by moving my body (shown on the video display) to avoid images of rocks. This consumer product is of interest because various groups are working on it to both understand how it works and to apply it to practical manufacturing problems. It has the advantage of providing 3-D images interactively at a very low cost. With this technology, an invisible (i.e., infra-red) array of dots is projected from one end of a bar and a camera at the other end of the bar is used to image the dots. Dynamic triangulation is used to find distances. The triangulation aspect is simply demonstrated by deliberately bending the bar, which will change the detected distances as anticipated.1

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2. Time-of-Flight Optical Imaging Time-of-flight imaging measures the time delay between when a beam is sent to an object and when it is received by a sensor. It is used in familiar applications, such as radar (to determine the 3-D distance to airplanes) and

3-D IMAGING

ultrasound medical imaging (to image fetuses within the pregnant mother). LIDAR is the optical equivalent of RADAR. LIDAR is an acronym for Light Detection And Ranging. It is essentially a time-of-flight, range-imaging technique.

The distance to a surface can be measured using the time delay between pulses, as well as the phase and amplitude of an RF modulated illuminating beam and the return beam. [Note: The speed of electromagnetic waves is 299,792,458 meters per second (3.00 x 108 m/sec or 3.3 nanoseconds/meter). Electronics with time responses up to 1000X less than nanoseconds are commercially available.] The seemingly relentless advances in electronics (Moore’s Law) have resulted in corresponding improvements in this technique. 3. Microscopy Remarkable advances continue to be made in 3-D microscopy, including near-field optical microscopy, atomic force microscopy and confocal microscopy. Information on atomic positions can be obtained. All of these techniques provide 3-D information at resolutions considerably better (e.g., nanometers) than that available from microscopy that is Rayleigh-Criterion (diffraction) limited to about one-half wavelength of the light used. • Near-Field Optical Microscopy This is done by placing the detector very close (distance much smaller than the light wavelength) to the specimen surface. In near-field scanning optical microscopy, the resolution of the image is limited by the size of the detector aperture and not by the wavelength of the illuminating light. In particular, lateral resolution of 20 nm and vertical resolution of 2–5 nm have been demonstrated. Dynamic properties can also be studied at a sub-wavelength scale using this technique. Near-field optical scanning is also used to determine the deflection of the cantilevered mechanical probe used in atomic force microscopy. • Atomic Force Microscopy Atomic Force Microscopy can have resolution to less than 1 nanometer.

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Think of a number ......... between 2 and 16… It is one of the primary tools for imaging, measuring and manipulating matter on the nanoscale. The information is gathered by sensing the pull on a cantilevered mechanical probe that has a tip with a very small radius. The probe is very precisely scanned near a surface using piezoelectric devices that control small, but precise, movements under computer control. The pull is between the tip of the probe and nearby atoms on the surface. In some units, the deflection of the cantilevered mechanical probe is gauged using near-field optical detection (as above). • Confocal Microscopy In a confocal microscope, the illumination is focused in a small area on the sample. The sensing optics simultaneously images the same focused area. The imaging process uses both spatial and spectral filters and results in increased resolution and optical contrast. Light from nearby sample volumes and from off-axis diffraction peaks are virtually eliminated. The 2-D image of a plane (a “slice” through the sample) is then formed by scanning—row after row of individual spots in a plane are simultaneously illuminated and imaged. The resulting 2-D image of rows in a plane is then a “slice” through the sample. The three dimensional image is formed by stacking these 2-D slices, similar to the way that biologists physically section a biological sample with a microtome and then reconstruct the 3-D physical sample. The slices in the confocal microscopy do not disturb the sample, and are thin. This basic confocal microscope was initially, and is still, used to image fluorescence from samples, but it has been expanded to non-fluorescent applications. Confocal microscopy offers several advantages over conventional optical microscopy, including the elimination of image degrading out-of-focus information, controllable depth of field and the ability to collect serial optical sections from thick specimens. One key to the confocal approach is the use of spatial filtering to eliminate out-of-focus light or glare in specimens that are thicker than the plane of focus. There has been a large expansion in the popularity of confocal microscopy in recent years. Dr. Norman N. Axelrod (Norman N. Axelrod Associates, New York, NY) does contract development and consulting on challenging electro-optical sensing and control systems. For more information, visit www.axelrodassociates.com, call (212) 741-6302 or e-mail [email protected].

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REFERENCES

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1. Electronics Design, Vol. 55, No. 5, April 7, 2011, p.28: “How Kinect Really Works”

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M A C H I N E V I S I O N 10 1

What

Machine Vision Solution is Right for You? BY FOLLOWING THIS EASY, THREE-STEP PROCESS, YOUR SELECTION OF THE RIGHT VISION SOLUTION FOR YOUR NEEDS WILL BE BETTER ASSURED. Kevin Shayne

There are three critical factors in determining the right machine vision solution: • Know yourself • Know the marketplace • Know the products Typically, individuals address the items above in the opposite priority as listed and sometimes completely leave out one or more of the items from examination altogether. This happens because many times as problems arise our tendency is to try to quickly find a solution. So, we look for a product that addresses our perceived need in the moment. By following that path, both understanding the marketplace and knowing your own capacity, limitations and complete needs are minimized or totally ignored. The danger is that the right machine vision solution, one that addresses your com-

tech tips Ask yourself “what are my support capabilities?” and “What are my expectations?”

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plete needs today and well into the future, may be totally overlooked. By following this easy, three-step process, your selection of the right vision solution for your needs will be better assured.

KNOW YOURSELF Let’s examine this concept of knowing oneself. This isn’t a deep philosophical exploration (although that may be enjoyable to explore over a holiday break or corporate retreat). Instead, for starters, we want to concentrate upon these important questions: • What is our internal machine vision support capability? This can include

There are three main categories or types of machine vision companies: Manufacturers, Systems Integrators and Solution Providers.

VISION & SENSORS | July 2011

such things as available development and project management resources, internal machine vision design and integration capability, experience with parts handling and presentation automation. • What are our expectations? Or another way to say it: What do we want and what do we need? You should have a pretty clear idea of what you want to achieve. Open discussion must come from all key players and there should be consensus of some kind. Expectations often turn into final requirements providing direction to the project. A failure to provide clarity will certainly come back to implementing a less-than-ideal solution and to create avoidable disharmony in your ranks. It is especially important that your organizational communication is cohesive and continuous in terms of key deliverables and the results of any implementation. • Is there project support? Issues such as funding, desire, ROI, come into play here. Who is driving this, who needs to be convinced, and who are the advocates? These are critical elements in knowing yourself as an organization.

THE MACHINE VISION MARKET Here’s the skinny on the machine vision marketplace. There are three main categories or types of machine vision companies. There are: 1. Manufacturers – Their focus is primarily on creating or developing hardware or software. They concentrate on products and utilize a distribution channel to allow customers or systems integrators to execute actual project implementation. Typically, they aren’t directly involved in implementations and, if they are, it is typically for large projects or highly constrained ones.

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2. Systems Integrators – Their focus is on project implementation and normally utilize either home spun products or a mix of packaged products they represent. Their capability to implement projects varies tremendously. Normally, they are limited in their organizational size, knowledge, product offerings, experience, relationships and capability. Niche capability is somewhat critical for a systems integrator in order for them to survive and to be successful over the long term. This makes them less viable for any multi-disciplinary projects. 3. Solution Providers – Their focus is on solutions and, typically, they have developed products internally to support their machine vision implementations. Coming from a multi-disciplinary perspective they have the internal knowledge, expertise and experience to deliver soup to nuts solutions that include automation, engineering, customization, integration, etc. Solution providers provide the best mix of a manufacturer with that of a systems integrator. As a manufacturer they have deep product expertise and as a system integrator they have on the ground experience with implementations. As a solutions provider they have extensive ability to provide integration and broad project implementation capabilities (such as systems integration, automation, product handling).

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After determining what you need (Question #1) it is a great idea to drill down and determine if the companies you are looking at match up to your requirements. For example, finding a manufacturer and expecting them to work with you on a small project without any internal staffing or capability would be folly. Likewise, partnering with a systems integrator if you require process improvement, skilled design or integration expertise, would be equally unwise. However, if you have extensive in-house capabilities, buying products from a manufacturer and integrating them yourself may suite your needs just fine.

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VISION & SENSORS | July 2011

Here’s a shortcut to the categories of products available for machine vision. In the vision arena there are primarily two categories: 1. Smart Cameras – cameras and integrated software (embedded in the camera) is the primary 2. Intelligent Solutions – multifunctional high performance solutions that typically use open architecture Smart Camera is a generic term that has generally come to mean a camera enabled with on-board processing. The degree of successful implementation or capability therein ranges tremendously. There is no list of features or even standards surrounding “smart cameras.” Smart cameras have had an uneven history; however, their marketing has been extremely successful. They started from the bottomup and have been the ‘simple’ solution for such applications as bar code identification, presence/absence and product feature inspection. Smart cameras can be imple-

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mented by experienced and knowledgeable internal staff when the end result purpose is limited in scope. However, presentation of product to cameras and other functionality (lighting and reject handling) typically requires the use of a systems integrator to assist. When looking at smart cameras the tendency to underestimate the project requirements and demands will be high. It is essential to resist that tendency and to be rational in your selection of the right machine vision product. However, as long as the requirement is constrained and limited in terms of features being examined smart cameras may work. Nonetheless, smart cameras have a multitude of downsides. These are rarely considered because the marketing of smart cameras leads customers to believe this is the best option. On the other hand, Intelligent Solutions provide an extremely solid alternative for growth, flexibility, process improvement and information distribution. Intelligent solutions are based upon obtaining best of breed components (such as cameras, lighting, triggering and automation systems—robots, handling) combined with purpose built machine vision software and hardware. Intelligent solutions typically deliver a platform for addressing diverse needs and requirements (often in a custom or near custom fashion) in a very robust package. Of course, this can vary from vendor by vendor but overall it does hold true. Here are a few examples of where intelligent solutions are a more appropriate choice then smart cameras: • When many smart cameras would be required to handle a job—failure to scale • Where reporting, data distribution and process analysis are important • High manufacturing speed demands • Complex inspections which can include many and diverse inspections (e.g. metrology, surface inspection), and/or difficult inspections • When there’s a need for customization, integration and/or specialized equipment

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THE BEST SOLUTION? This is certainly a starting point. Secondary factors such as partner/ vendor selection are better left to another discussion. Stick to getting the best solution and you will surely be far ahead of the pack: (1) Know

Yourself; (2) Know The Marketplace; (3) Know the Products. Kevin Shayne is Director of Marketing for Boulder Imaging.

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CASE STUDY

Putting It

smart camera-based vision inspection stations. These applications vary from absence/presence to gauging/measurement. The addition of machine vision to the line came about when the FOR customer expressed concern with the ﬁ nal test machines failing engines due to operator errors during assembly. ThyssenKrupp presented a camera-based solution similar to what they had developed in the past for other engine builders. This solution would use vision inspection at the staA manufacturer of construction tion where the parts and heavy equipment commissioned ThyssenKrupp Engineerwere being installed. ing to build an engine assembly Any errors would line for a new plant. In addition to its role as a line builder, then be ﬁ xed at the ThyssenKrupp had the mandate assembly station. to provide this factory with a

All on the Line MATROX IMAGING SMART CAMERA PROVIDES THE VISION ENGINE ASSEMBLY AND TEST SYSTEM.

machine vision solution for the line. Source: ThyssenKrupp System engineering, Inc.

ThyssenKrupp System Engineering, Inc. is a world leader in the design and manufacture of turn-key assembly and test systems for automotive powertrain components, including engines, transmissions, and axles. A manufacturer of construction and heavy equipment recently commissioned ThyssenKrupp System Engineering (Auburn Hills, MI, USA) to build an engine assembly line for a new plant in the U.S. Southwest. In addition to its role as a line builder, ThyssenKrupp had the mandate to provide this factory with a machine vision solution

for the entire engine assembly line. Acting as the system integrator, ThyssenKrupp supplied the vision, mechanical and electrical systems, Programmable Logic Controller (PLC) connectivity, and training of plant staff. The ﬁ rst steps of the vision solution were developed using six Matrox Iris GT smart cameras. As an engine moves down the line, it goes through multiple

ADDING VISION TO THE ENGINE LINE

The heavy equipment manufacturer was a brand new ThyssenKrupp System Engineering customer who was skeptical about using vision-based inspection as part of their assembly line. The manufacturer questioned the reliability of the results, and had concerns about the dependability and maintainability of vision. ThyssenKrupp Program Manager Pat Coughlin explains, “Working with the customer, we determined that the part complexity, combined with the extensive teardown and rework required if an error is made, justiﬁed the use of in-station inspection. A camera was a perfect ﬁt because it can handle the part variation and can be located completely out of the operator’s workspace.” Application A uses one Matrox Iris GT smart camera to verify that the crank gear and water pump gear are aligned properly. The crank gear

beneﬁts The camera-based solution uses vision inspection at the station where the parts were being installed and any errors would then be ﬁxed at the assembly station.

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In addition to building a ﬂowchart, the IDE lets users directly design a graphical operator interface to the application, which presents the inspected image as well as inspection statistics and controls.

VISION & SENSORS | July 2011

Design Assistant’s subﬂowchart feature allows the inspection logic to be neatly separated from the communication and data logging logic.

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has a carrot feature and the water pump gear has a painted yellow line. The yellow line must be pointing at the carrot. Application B uses four Matrox Iris GTs. Cameras 1 and 2 both verify the presence and location of eight water seals. Camera 3 determines the presence and location of a drainback seal, another gasket, and eight water seals. Camera 4 veriﬁes that only a single head gasket is installed. Application C uses a single Matrox Iris GT to verify that the timing mark (painted line) on the idler gear is between two painted teeth on the crank gear.

SMART-CAMERA-BASED VISION INSPECTION The vision system is based on several Matrox Iris GT smart cameras. The applications were developed with Matrox Design Assistant, an integrated development environment that is bundled with the smart camera. Matrox Design Assistant is an integrated development environment (IDE) that lets users create machine vision applications by constructing a ﬂowchart instead of coding programs or scripts using languages like Visual Basic, C, C++ or C#. Once development is ﬁ nished, the project (or ﬂowchart) is uploaded and stored locally on the Matrox Iris GT. The project is then executed on the smart camera without the need for any companion PC and, in this case, is monitored and controlled from the PLC over an Ethernet link. A Siemens Human Machine Interface (HMI) panel is located at each assembly station. It provides the operator with the engine build type, cycle time display and any speciﬁ c information required at that station. The HMI also displays the camera image so that the operator can look at the inspection in the event of a failure. He then identiﬁ es the object that failed and takes corrective action. The network connection is used for communication with the same Siemens

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PLC that runs the entire assembly line using the TCP/IP protocol. The camera acts as a server and the PLC is the client. The camera monitors the connection from the PLC and if the connection terminates, the camera automatically makes the communication port once again available for the PLC to reconnect. The PLC is also responsible for sending the proper recipes to the camera depending upon the engine type in station. In addition to building a ﬂowchart, the IDE lets users directly design a graphical operator interface to the application, which presents the inspected image as well as inspection statistics and controls. The operator interface displays annotations and pass/fail statistics. No control was given in the operator interface that would allow changes to be made to the project.

A number of Design Assistant tools or ﬂowchart steps were used. “Image processing operations enhanced and transformed images in preparation for subsequent analysis,” says ThyssenKrupp Controls Engineer Matthew Maitland. “As well, objects were analyzed using image intensity. Measurement tools, which are used to assess parts’ manufacturing quality, performed 2D geometric dimensioning and tolerancing. The metrology step was used for identifying features and to take measurements between them. For example, angle of crank was veriﬁed as ‘top-dead center’ using angle between center of crank and ’arrow’ pattern. The measurement step was used for Application B - Camera 4 to determine the thickness of the head gasket. A variety of tools were used for redundant detection of features so if one tool failed, a secondary tool

July 2011 | VISION & SENSORS

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CASE STUDY

Two Matrox Iris GT smart cameras verify the presence and location of eight water seals. Source: ThyssenKrupp System engineering, Inc.

would be used for detection. The pattern matching step, as well as the model ﬁ nder tools—which locate objects using their geometric features—were used, depending on the object, for both ﬁ xturing and object detection/measurement.” Design Assistant’s subﬂowchart feature allows the inspection logic

to be neatly separated from the communication and data logging logic. This helped simplify the design process and will facilitate future maintenance. Subﬂowcharts allow for a common programming architecture between cameras with the main program and custom subﬂowcharts for different program numbers/complex-

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VISION & SENSORS | July 2011

ity. The subﬂowcharts contain only vision tools, which make it easy to troubleshoot when complex modiﬁcations are required. Other smart cameras were evaluated by ThyssenKrupp for the vision system but the Matrox Iris GT offered some key advantages. Maitland explains, “Matrox products offer features best suited for this application at a competitive price.” He continues, “Matrox Iris GT also has a lot more memory than other smart cameras. We can load multiple jobs (inspections) in memory simultaneously. Other smart cameras’ memory limitations would have required that we load one job at a time. As well, images would have to be stored on a separate PC, since there would be inadequate on-camera storage. Design Assistant’s ﬂowchart logic also allows us to branch and execute different inspections within an application. In contrast, other smart cameras only support the development of standalone inspections—an application needs to be shut down before the next one can be loaded and executed.” The engine line’s vision system was deployed in September 2010. “Deployment went smoothly,” explains Maitland. “Application troubleshooting was handled remotely—it’s easy to debug a ﬂowchart when the logic is visually presented as interconnected blocks.” ThyssenKrupp handled the majority of these technical issues and only required support from Matrox Imaging on a few occasions during the initial development phase. It was on those rare occasions, however, that ThyssenKrupp appreciated having direct access to experienced engineers at Matrox. Fabio Perelli, Smart Camera Product Manager for Matrox Imaging, adds, “ThyssenKrupp vision developers are extremely experienced—in fact, they provided us with valuable feedback on our smart camera software—some of which has already been incorporated into Matrox Design Assistant.”

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VISION & SENSORS

CASE STUDY

As well, ThyssenKrupp only needed to spend a day training plant staff on the vision system. And so far, there have been no technical issues that have required ThyssenKrupp to send staff on-site to troubleshoot.

MOVING FORWARD Three inspection stations on the engine assembly line currently use vision and another station was added in January 2011. Since the ﬁ rst three stations have proven to be effective and maintenance-free, the engine manufacturer is looking to use Matrox Imaging vision components to ensure that many more assembly processes are being completed properly. Matrox Imaging (800) 804-6243 www.matrox.com/imaging

The operator panel presents the inspection image, as well as inspection statistics and controls. The operator interface displays annotations and pass/fail statistics. Source: ThyssenKrupp System engineering, Inc.

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VISION & SENSORS

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FLUORESCENCE MICROSCOPE The Keyence BZ-9000 (BIOREVO) is a fully integrated system capable of performing fluorescence, bright field and phase-contrast imaging on a variety of specimen holders (slides, dishes, well-plates)–without the need for a darkroom. By integrating a fully motorized, six-objective lens revolver, motorized stage, electronically-controlled filter turret and built-in sample enclosure, the BZ-9000 is able to reduce the amount of tabletop space required for a conventional fluorescence microscope by over 40%. The BIOREVO is able to switch between up to four different fluorescent channels with just a click of the mouse, automatically adjusting the filter, exposure time. This simplified process is able to reduce the amount of time needed to perform research and analysis, while preserving the longevity of the specimen. The BZ-9000 incorporates a single high-resolution, high-sensitivity 12-bit monochrome camera that can easily switch to color imaging with the click of a mouse. A unique navigation system allows users to easily locate areas of interest on a specimen when at high-magnification by using a low-magnification image for reference. The BZ-9000 is also able to overcome limitations associated with traditional fluorescence microscopes by incorporating a Z-stack and image stitching function. Users can stitch up to 1,200 images in XY directions to capture a large field-of-view, even when at high-magnification. A Quick Full Focus and Z-stack function captures fully-focused images in a matter of seconds. The BIOREVO also provides options for quantitative analysis, including standard two-dimensional measurements, cell counting and brightness analysis. A RealTime 3D Module is able to generate a three-dimensional image of a fluorescent specimen, eliminating some of the reliance on laser confocal systems.

PCB Piezotronics’ 261A Series Triaxial Force Link Sensors, from the Test and Measurement Division, simultaneously measure dynamic and quasi-static forces in three orthogonal directions (X, Y and Z axes). The sensors are used in biomechanical research, modal analysis, cutting tool forces, automotive chassis dynamics, force limited vibration testing of aerospace structures and force dynamometers. Series 261A are conveniently provided in a preloaded flange mount configuration allowing easy eight screw installation and feature full scale measuring ranges from 500 lb to 4,000 lb (2.2 kN to 18 kN in the X and Y directions, and from 1,000 to 10,000 lb (4.5kN to 45kN) in the Z direction in three mechanical envelopes. All ranges are available in a choice ICP® or change output versions as well as English or metric threaded mounting threads. PCB Piezotronics www.pcb.com

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AUTOMATED INSPECTION SYSTEM Cincinnati Automation’s new Automated Inspection System is designed to check medical device packaging and verify correct assembly of small medical device kits. The system includes two independent Keyence machine vision controllers with high resolution cameras and LCD displays. One vision system uses blue LED lighting, blue pass filters on lens and is programmed to inspect the seals around a clear cellophane package.

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VISION & SENSORS | July 2011

The second system utilizes an integrated LED back light conveyor and is programmed to check for contamination in the package. This system is also programmed to verify kit assembly. The system includes a userfriendly touch screen HMI for quick and easy part number selection, good, bad and total parts inspected counts. Cincinnati Automation (859)371-5070 www.cincinnatiautomation.com

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ANALOG FRAME GRABBER

GIGE VISION CAMERAS

Bitflow’s Alta-AN1 analog frame grabber is versatile and requires only simple cabling. The Alta-AN1 can acquire from almost any analog camera on the market, from high speed asynchronous-reset monochrome cameras to super high resolution color HDTV cameras, saving the user the cost of a digital system (camera, cabling and frame grabber) where analog resolution will suffice. The Alta-AN1 is a half-size x4 PCI Express board supporting total data rate up to 1.0 GB/S, and can be configured for unique triggering modes, gain/offset and destination buffers. It features a discrete analog front end with three Analog-toDigital converters, plus provides power to the camera to further simplify its deployment. BitFlow supports the Alta-AN1 with its Software Development Kit (SDK), available for both 32-bit and 64-bit Windows platforms. The SDK is board family generic, meaning it will work with all of BitFlow’s current and future frame grabbers. The kit provides drivers, DLLs and configuration utilities for those interested in using third party software. While the Alta-AN1 supports a single camera, BitFlow also offers the Alta-An2 for two cameras, and the Alta-AN4 for four. All BitFlow frame grabbers are manufactured in the United States.

Point Grey’s new Flea3 FL3-GE series of GigE Vision digital cameras feature an ultra-compact size of just 29 x 29 x 30 millimeters. The first available models use monochrome and color versions of the popular Sony® ICX445 CCD, a high sensitivity 1.3 megapixel 1/3-inch EXview HAD image sensor that runs at 30 FPS. Every Flea3 GigE camera is equipped with an industry-standard C-mount lens holder, removable IR cut filter (color models) / optical window (monochrome models), and a 12-bit analog-to-digital converter.

BitFlow (781) 932-2900 www.bitﬂow.com

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2-D LASER PROFILE GAGING MACHINE Cincinnati Automation’s automated 2-D Laser Profile Gaging Machine is designed to measure step changes between two surfaces on a critical edge of parts to 0.001” accuracy. The gaging system controller could also be programmed to check gap width, intersection angle and flatness of these and similar parts. The machine includes two Keyence LJ-G series 2-D laser displacement sensors with controller and large LCD display. The system includes a user-friendly touch screen HMI for quick and easy part number selection, good, bad and total part counts. Cincinnati Automation (859) 371-5070 www.cincinnatiautomation.com

NAVIGATION SYSTEM JEOL offers a new point-and-shoot navigation system that makes finding precise locations on a sample both fast and easy for SEM and EPMA users. The Stage Navigation System combines Stage Navigation Software with an externally-mounted 3 Megapixel CMOS color digital Stage Navigation Camera that functions as a low magnification optical microscope. The external camera eliminates the need for a dedicated port on the electron column. The user simply records an image of the sample, sends the image to the SEM, places the sample on the sample stage, then clicks on the recorded image to specify the area of interest. The software automatically positions the stage with pixelprecision to the exact area of the sample to be examined. JEOL USA www.jeolusa.com

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July 2011 | VISION & SENSORS

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Contact your Quality Marketing Manager today! Group Publisher Barbara Grim Bill DeYoe Buck Bicek Darrell Dal Pozzo (856) 358-4800 (704) 822-6434 (630) 971-0904 (847) 405-4044 Fax: (856) 358-0900 Fax: (704) 822-6834 Fax: (248) 502-1086 Fax: (248) 502-1024 [email protected] [email protected] [email protected] [email protected]

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AEROSPACE A SPECIAL SECTION TO

MAGAZINE

AS9100C Evolving to Align with the Globalization of Aerospace Eddy Current Inspection: Sliding Probes p. NDT14 Magnetic Particle Theory and Processing Steps p. NDT6

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AEROSPACE

| TABLE

OF CONTENTS

JULY 2011 DEPARTMENTS

10 MAGNETIC PARTICLE INSPECTION

6NDT Magnetic Particle Theory and Processing Steps The apparent simplicity of the magnetic particle process can be misleading and it is often incorrectly assumed that the process steps are simply magnetizing, applying the particles and inspection.

2 NDT

Editor’s Note Non-Destructive Test Takes Flight

4 NDT

Industry News

20 NDT

Tech Showcase Borescopes

21NDT

Case Study Lending a Hand with Precise Tooling

24 NDT

Products

IBC NDT Advertising Index

IN THE NEXT ISSUE

AS9100

10NDT AS9100C This standard is evolving to align with the globalization of aerospace.

Thermography

FATIGUE TESTING

Laser Ultrasonics

14NDT Eddy Current Inspection: Sliding Probes

Computed Tomography

NDT technicians armed with an eddy current instrument and a sliding probe can inspect almost any aluminum-skinned aircraft.

6

LIGHTING

18NDT The History and Evolution of White Light Inspection Sources for Aerospace LED white light source is well-suited to applications in aerospace, including the visual inspection of small parts, such as those used in aircraft turbine engine assemblies.

ABOUT THE COVER Even though the July 8 ﬂight Atlantis will be the 135th and ﬁnal mission of the shuttle program, it is by no means the end of the Aerospace program in the U.S. or around the world.

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14

July 2011 | Aerospace Special Section 1

AEROSPACE

| EDITOR’S

NOTE

Non-Destructive Test Takes Flight BY DARRYL S ELA N D, EDI TOR I N CHI E F

As I write this, NASA is fueling space shuttle Atlantis. Not for the historic last ﬂight of the agency’s 30-year shuttle program, but to test repairs to the shuttle’s external fuel tank. Patches were applied to the aluminum struts in the center of the tank to address the very same issue that kept shuttle Discovery grounded last year. Reportedly, the brackets were made from an aluminum alloy that was more brittle than that of the tank, and that, along with assembly issues, led to the cracking on Discovery’s tank. Liftoff for Atlantis is scheduled for July 8. In the meantime, NASA Technicians will X-ray the brackets on the tank to ensure the soundness of these repairs and check for cracking in the fuel tank support brackets. Additionally, NASA is still analyzing issues from Endeavour’s recently completed ﬂight. A glob of grease caught

traveled 122,883,151 miles after delivering the Alpha Magnetic Spectrometer-2 (AMS) and other critical supplies to the International Space Station. Atlantis’ mission will carry the Raffaello multipurpose logistics module to deliver supplies, logistics and spare parts to the International Space Station. Atlantis also will ﬂy a system to investigate the potential for robotically refueling existing spacecraft and return a failed ammonia pump module. Even though the Atlantis ﬂight will be the 135th and ﬁ nal mission of the shuttle program, it is by no means the end of the Aerospace program in the U.S. NASA is under presidential direction to “shift from orbital ﬂ ights to expeditions beyond.” NASA already has a number of missions on the books for the rest of 2011. For instance, on August 5 the solar-

Liftoff for Atlantis is scheduled for July 8. In the meantime, NASA Technicians will X-ray the brackets on the tank to ensure the soundness of these repairs and check for cracking in the fuel tank support brackets. ﬁre near the left main landing gear when Endeavour landed on June 1. Also, according to NASA spokesman Allard Beutel, the loss of foam insulation from Endeavour’s tank during liftoff on May 16 was age related. The tank was 10 years old, the oldest tank ever ﬂown. The issue of aging in space ﬂight is not only pertinent from the standpoint of the number of years, but also from analyzing the time frame of a typical mission. For example, during Endeavour’s most recent mission, its 25th and ﬁnal ﬂight, the shuttle spent 299 days in space, orbited the Earth 4,671 times and

2 Aerospace Special Section | July 2011

peratures, humidity sounding, land and ocean biological activity and cloud and aerosol properties. And this type of exploration is not limited to the U.S. The space race between the United States and the Soviet Union in the 1960s has lead to just about every industrialized nation having its own aerospace program, from French and Swedish warplanes to the space agencies of the European Union, China, and India. Even Pakistan is perfecting missile technology and other aerospace engineering projects under its Institute of Space Technology. This “Globalization” of the Aerospace industry has lead to the need for updated standards. Read about the updates to the AS9100 standard in this month’s NDT cover feature, “AS9100C: Evolving to Align with the Globalization of Aerospace.” Also, keep up with the latest technologies, processes and theories for non-destructive testing in the Aerospace industry with “Magnetic Particle Theory and Processing Steps,” “Eddy Current Inspection: Sliding Probes,” and Greg Falk’s feature, “The History and Evolution of White Light Inspection Sources for Aerospace.” Enjoy and thanks for reading!

powered Juno spacecraft is to orbit Jupiter’s poles 33 times to ﬁnd out more about the gas giant’s origins, structure, atmosphere and magnetosphere. In September, The Gravity Recovery and Interior Laboratory mission’s primary science objectives will be to determine the structure of the lunar interior from crust to core and to advance understanding of the thermal evolution of the moon, and in October The National Polar-orbiting Operational Environmental Satellite System Preparatory Project (NPP) mission for NASA and NOAA is to measure Earth’s atmospheric and sea surface tem-

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AEROSPACE

| NEWS

MAG ACQUIRES FOREST LINÉ INDUSTRIES ERLANGER, KY– MAG has reinforced its global technology leadership in metal cutting and composites processing by acquiring French company, Forest Liné Industries Group (FLI). Forest Liné specializes in manufacturing systems for aerospace applications, dies/molds, large parts, titanium and composites processing. The company is a technology leader in composite wing and wing box applications, and operates sites in France, Germany, China and Canada, employing about 300. Jean Bertrand Prot will continue as President and CEO of FLI and join the MAG Executive Board. “This acquisition gives MAG another signiﬁcant point of access to aerospace composites technology, manufacturing resources and demonstration facilities, as well as additional market and customer segments,” says Dan Janka, president of MAG Global Industrial Systems. “Liné has always been an innovator, and its technology portfolio is highly complementary with our own, so we anticipate a wide range of new opportunities to result from this acquisition.” Like MAG, Liné is a supplier of both automated tape laying and ﬁber placement systems. Lightweight and rigid composites are widely used throughout the aerospace industry and in renewable energy systems, such as wind turbines. MAG, through its European business, MAG Europe GmbH, with headquarters in Göppingen, Germany, has acquired 100% of the shares in the Forest Liné Group.

WEST PENN TESTING CONTINUES AEROSPACE TESTING PROGRAM NEW KENSINGTON, PA— West Penn Testing Group, a provider of material testing services, has spent ﬁve years preparing for the next aerospace up-cycle. “Today, suppliers to aerospace OEM are less likely to be surprised by a surge in orders,” says Albert Fletcher, general manager, West Penn Testing. “The reason is, a number of airframers and jet-engine manufacturers have committed to sharing production forecasts with their suppliers. Some refresh this demand information quarterly, looking out 12 months. This information sharing helped us predict the current rise in bookings and more accurately estimate the demand on the horizon. We started using these forecasts ﬁve years ago. As a consequence, we have improved our ability to anticipate demand.” West Penn says the biggest bottleneck to responding to upticks in demand is the availability of trained inspectors on staff.

MECNOV ANNOUNCES ALLIANCE WITH MIDAS-NDT SYSTEMS QUEBEC, CANADA—Mecnov NDT Systems announced today that it has ﬁ nalized an agreement with UK-based Midas-NDT Systems to collaborate on the sales, promotion and manufactur-

4 Aerospace Special Section | July 2011

ing of ultrasonic inspection systems for advanced composite materials used in aerospace applications. The collaboration between the two companies, which manufacture automated inspection systems for a variety of industries such as aerospace, automotive, oil and gas, aims to diversify revenues for Mecnov and expand Midas-NDT’s geographical bases. Since the agreement was concluded in February 2011, Mecnov and Midas-NDT have been actively bidding conjointly on various projects.

FRANK M. FOELLER OF THE BOEING COMPANY TO DELIVER KEYNOTE AT CMS CONFERENCE PHOENIX, AZ—Frank M. Foeller of The Boeing Company will be the keynote speaker at the 27th Annual Coordinate Metrology Systems Conference (CMSC), July 25 – 29, 2011 at the Arizona Biltmore Hotel and Spa in Phoenix, AZ. Foeller is the director of tooling operations for Boeing Defense System, and leader of the Boeing enterprisewide Tooling Process Action team. Foeller will discuss the beneﬁts realized by The Boeing Co. from 3-D metrology technology advancements. His conference session is titled “Portable Metrology Advancements Changing the Game for Tool Fabrication and

Aircraft Manufacturing and Assembly Investigation.” “To remain competitive in the future, we need to invest in the technological advancements and applications of this technology,” Foeller says. “The industry must continue to work together with suppliers, users, and customers to further the progress.”

PRATT & WHITNEY AWARDED $1.13B CONTRACT FOR F135 ENGINE PRODUCTION EAST HARTFORD, CT—The U.S. Department of Defense has awarded Pratt & Whitney a $1.13 billion contract for F135 production engines to power the F-35 Lightning II. Pratt & Whitney and the DoD have reached an agreement on price and terms for the LRIP 4 contract, originally awarded in July 2010, which contains ﬁ xed-price and cost-plus incentive fee elements. This low rate initial production (LRIP) contract includes production, spare parts, sustainment and delivery of the fourth lot of F135 engines. Pratt & Whitney is a United Technologies Corp. company. “This contract provides our customer with a 15% savings on the conventional takeoff and landing/carrier variant (CTOL/CV), compared to LRIP 3, and demonstrates our commitment toward meeting aggressive cost reduction goals for the F135 engine,” says Bennett Croswell, president of Military Engines, Pratt & Whitney. “It also speaks to the maturity of our engine, which builds on the proven technology of our F119 engine. The F135 engine has powered all 868 F-35 ﬂights, including 100 vertical landings in the short takeoff/verticallanding (STOVL) conﬁguration.” The fourth lot of F135 engines includes 18 conventional take-off and landing (CTOL) and 19 STOVL engines. Deliveries for this lot are slated to begin in the fourth quarter of 2011. The engines delivered in LRIP 4 will support the U.S. Services, the United Kingdom and the Netherlands.

AEROJET NAMES NEW VP OF MISSILE DEFENSE UNIT SACRAMENTO, CA—Aerojet, a GenCorp company, announced that Michael Bright has joined the corpora-

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tion as vice president of the Missile Defense business unit. Bright comes to Aerojet from Lockheed Martin with a long history in the missile defense community. Bright has a bachelor of science degree in physics from Fort Lewis College and has completed master’s-level courses in aerospace and systems engineering, leadership, program management and ﬁ nancial strategies. Bright replaces Pete Massey, the current Missile Defense business unit leader, who will be leaving his position to join the company’s business development and strategy department. In his new role, Massey will enhance and expand Aerojet’s external business relationships throughout the national and international marketplaces.

to 50% throughout the next three years. Increasing demand for commercial aircraft, however, does not come without its challenges, and the guide-path to meeting global demand will be bumpy. Original-equipment manufacturers (OEMs) will be forced to ramp up production while simultaneously trying to innovate and develop products to meet demand for more fuel-efﬁcient aircraft.

Suppliers—who largely decreased capacity after suffering through the recession—will also face capacity and talent-acquisition constraints as they try to meet demand, and according to the AlixPartners study. There is signiﬁcant risk, says the study, that commercial-sector suppliers will not be able to keep up with aggressive new manufacturing demands.

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AEROSPACE AND DEFENSE SECTOR FACES SUPPLY CHAIN SQUEEZE The worldwide aerospace and defense industry should be gearing up for “severe supply-chain pressures” in the years ahead, newly published research from business-advisory firm AlixPartners warns. ”The aerospace and defense industry globally will be facing tough and contradictory burdens in the next few years, as the need to meet an anticipated 25% jump in commercialaircraft deliveries by 2014 contrasts with further belt-tightening of nations’ defense budgets in the wake of widespread budget deficits—both of which could lead to severe supply-chain pressures,” the study reads. The report notes that, while impacted, the global aerospace and defense industry emerged from the economic downturn relatively well, due largely to increased demand in the defense sector, and cost-cutting. According to the study, the near-term outlook for commercial aircraft is positive due largely to increasing air-trafﬁc demand globally, which is expected to grow 5.5% by 2012 alone. Asia and the Middle East, says the study, will enjoy 35% of all demand increases over the long term. Rising fuel prices and the need for more-efﬁcient aircraft are already causing heightened demand for new aircraft, per the study. It notes that this year, for the ﬁrst year ever, commercial-aircraft deliveries globally are set to exceed 1,000 and that global aircraft production is expected to increase 30%

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July 2011 | Aerospace Special Section 5

AEROSPACE

| ADVANCES

Bluelight Inspection

Magnetic Particle Theory and Processing Steps The apparent simplicity of the magnetic particle process can be misleading and it is often incorrectly assumed that the process steps are simply magnetizing, applying the particles and inspection. BY DE N N IS G. HUN LEY, DE BBI E S HRE VE , PAT RI CK R. JE NK I N S AN D C H AR L E S MAZ E L

M

agnetic Particle Testing is performed by inducing a magnetic ﬁeld in ferromagnetic material and covering the surface with magnetic particles. Surface and near-surface discontinuities will distort the magnetic ﬁeld and create a leakage ﬁeld. The magnetic particles will concentrate near the leakage ﬁeld, thus indicating their presence by Visible Light or Black Light. The apparent simplicity of the magnetic particle process is misleading. It is often incorrectly assumed that the process steps are simply magnetizing, applying the particles and inspection. This misunderstanding results in the

assignment of personnel with little or marginal training who are not aware of the importance of their particular tasks and the effects they have on the overall process. The magnetic particle method requires a diligent awareness of each processing step from initial application to process completion.

MAGNETIC PARTICLE MATERIALS Fluorescent particles are used in the wet method to aid visibility, which requires the use of a black light and ﬂuoresce at 365 nm in the longwave region. The particles are suspended in water or oil. To achieve the required

test sensitivity, the particle concentration in the bath must be correct and a water based material must have the correct chemistry. Magnetic Particles must possess two important characteristics: • High permeability • Low retentively Magnetic particles containing these characteristics will give maximum response in a leakage ﬁeld, but will not remain magnetized when the magnetic ﬁeld is removed. The shape of the magnetic particle should be smooth and must have a high degree of mobility and still have substantial attractive power. There are two types of magnetic particles: Iron Oxides (Iron and Oxygen combination) and “Pure” Iron. It is important to have an understanding of the type discontinuity that needs to be detected. Either particle is functional, but chosen dependent upon the size discontinuity. Iron Oxides are ﬁner, lighter particles and ideal for very tight, critical discontinuities. The Iron Oxide will stay in suspension with simple agitation. The Iron Oxide shape can be controlled by the oxidation/reduction process. The Iron Oxide will remain in the discontinuity more effectively than the “Pure” Iron. The “Pure” Iron particles are larger in particle size and can be used to detect medium to large discontinuities. The geometry and size of these particles will render a much brighter particle than the Iron Oxide particle. The Iron particles will not stay in suspension as easy as the Iron Oxides and requires a more aggressive, constant agitation. These Straight Iron particles will migrate quicker to the discontinuity than the Iron Oxide. Every application and discontinuity must be evaluated in the selection of the optimal particle size and type. Magnetic Particle Testing has many facets to consider when applying to a

TECH TIPS From ultrasonic phased array to digital radiography, technology has given the NDT technician improved capabilities.

6 Aerospace Special Section | July 2011

While there are many advantages to advanced NDT methods, it is important that the personnel performing these examinations be properly trained.

In order to progress to the advanced methods of NDT, it is important that the technician be familiar with the conventional methods of NDT. www.qualitymag.com

component. Once a speciﬁc component or part is determined, the testing sensitivity must be deﬁned. It is very important to monitor the inspection system to verify that the sensitivity of the component has not changed. In order to ensure magnetic particle testing results obtained are reproducible, it is critical to maintain consistent control over the magnetic particles in the system. This relates to controlling the concentration of the inspection bath and if in a water bath system, factors such as corrosion inhibition, wetting and shelf life properties must be considered as well.

APPLICATIONS In the magnetic particle testing method there are many variables to be considered—before talking about applications—and understood when choosing a magnetic particle type. The primary factor is the characteristics of the component part to be inspected. The following characteristics must be considered: • Magnetic properties • Size, shape, and complex dimensions • Probable discontinuities. • Surface condition • Intended use. • Manufacturing Process Having a good working knowledge of the part and possible discontinuities will provide a better solution for the magnetic particle choice, speciﬁcally in regards to complex parts, although either particle type may readily capture

Magnetic Particle Control Unit for FWDC, HWDC, AC Waveform Oscilloscope Waveform Monitoring.

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HWDC Waveform

the discontinuity, the inspector needs to consider the overall inspection area. With Flaw to Background interference always a concern, it is important to keep the background minimized. There are several factors that affect the background such as particle concentration, contamination, lighting, and particle types–iron oxide vs. pure iron. We recently have addressed a request to evaluate the best particle type for threaded products. As stated above, both particle types may readily capture the discontinuity; however, their backgrounds will remain uniquely different. Due to the ﬁ ner sizes of the oxides and slightly slower migration rates, the oxides “deposit” a more noticeable background. The thread size and the coarseness of the thread part surface can provide ample area for the particles to “lag” behind and generate a background. The iron particles with their slightly larger size and density may “move” over the threaded area in such a manner that the background appears less signiﬁcant, and these iron particles will migrate quicker to a discontinuity than the iron oxide particle. We evaluated a small pure iron particle and found that it generated less background and thus, a sharper contrast for the discontinuity. Our

evaluation also included a standard iron oxide particle at a concentration of 0.4ml, a standard iron oxide particle at a concentration of 0.15ml and a pure iron particle at a concentration of 0.15ml. The best results were using a low concentration of pure iron particles.

LIGHT SOURCING A relatively recent innovation is the introduction of alternatives to ultraviolet light to excite the f luorescence of magnetic particles. When the f luorescent inspection method was developed the only practical sources of high intensity f luorescence-exciting light were bulbs that created a discharge in mercury vapor. Mercury has intense spectral emission lines at 254 and 365 nm in the longwave ultraviolet region. The manufacturers of f luorescent magnetic particles successfully produced materials that f luoresced with adequate intensity when excited by these lights. Since the only concern was that the magnetic particles ﬂuoresce under 365nm excitation, their response to other wavelengths was unimportant and not controlled for. It turns out that the same particles can indeed be excited by other wavelengths, both in the

July 2011 | Aerospace Special Section 7

AEROSPACE

| ADVANCES

Ultraviolet Light Inspection

ultraviolet and the visible. There are two basic ways to determine whether another wavelength will make magnetic particles ﬂuoresce: 1) try a light and see if it works; and 2) measure the

QLT04094Mach.indd 1

8 Aerospace Special Section | July 2011

excitation spectrum for the particle. The excitation spectrum is a measurement of the relative ability of different wavelengths of light to make something ﬂuoresce. Both methods demonstrate

that a wide range of wavelengths, in both the ultraviolet and the blue, can be used to make particles ﬂuoresce, sometimes with even greater brightness than when excited with an equivalent intensity of 365nm ultraviolet. The exact relationship can be determined by measurement, enabling one to specify the intensity of an alternative wavelength needed to excite the brightness that would you would expect from a conventional ultraviolet light that produces 1000 W/cm2. Intense blue light can now be easily produced through the use of high intensity light-emitting diodes (LEDs), and LED-based blue lights are now available on the market. The blue light reﬂected from the inspection area would interfere with and potentially mask the ﬂuorescence, so when using these lights it is imperative that the inspector wears yellow ﬁ lter glasses that completely block the reﬂected

3/2/09 10:46:50 AM

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blue and still transmit the ﬂuorescence with high efﬁciency. A scientiﬁc study on the use of blue light in combination with yellow ﬁ lter glasses for magnetic particle inspection has been conducted with successful results. The use of alternative excitation wavelengths, such as blue, for magnetic particle inspection is now permitted by ASME under the guidelines in Mandatory Appendix IV to Article 7 of the Surface Inspection code.

QUALITY CONTROL The most important requirement of a magnetic particle material manufacturer is to guarantee constant quality. This is achieved by implementing a stringent quality control program. The testing requirements are mandated by speciﬁcations such as AMS, ASTM, and various Military Speciﬁcations. Each batch of magnetic particles must meet the following criteria: color, contami-

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nation, concentration, ﬂaw to background check on a test piece with discontinuities, sensitivity, and durability. The sensitivity of Magnetic Particles is of major importance to ﬁ nding discontinuities. The sensitivity test requires the use of a Test Ring, called a “Ketos” ring which is an oil-hardened tool steel (AISI-01). When using this ring as a gauge for grading the sensitivity of magnetic particles, it is critical that all of these rings perform in exactly the same way; otherwise there is no perceived consistency in the particle performance, even if there was. We have concluded a year long study that shows there are signiﬁcant differences in test rings being used today, and equipment being used to magnetize this test ring. Because of this difference in test rings from various manufacturers we have contracted the certiﬁcation of all our rings to an independent calibration laboratory.

The magnetic particle machine used for magnetizing the test ring shall have a normal current waveform which has a rapid rise with no overshoot, stable and rapid fall as expected. If the waveform does not have these characteristics it will affect the results of the test ring. The magnetic particle machine that we use was ordered with an oscilloscope feature that monitors the waveform on each cycle. A picture is enclosed that illustrates the normal waveform for AC, HWDC, & FWDC magnetization. M . Dennis G. Hunley is a Consultant of Circle Systems, Inc [email protected] Debbie Shreve is in Research & Development for Circle Systems, Inc [email protected] Patrick R. Jenkins is President of Magwerks [email protected] Charles Mazel is President of Blueline ndt [email protected]

July 2011 | Aerospace Special Section 9

AEROSPACE

| ADVANCES

AS9100C Evolving to Align with the Globalization of Aerospace J OSEPH S O RREN TIN O

A

s a prerequisite to guarantee compliance with AS9100C, aerospace engineers must understand why the AS9100 standard was modiﬁed with the revisions present in its current version, “C.” Recent revisions to the ISO 9001 and AS9100C standards, as characterized in ISO 9001:2009 and AS9100C, expand and deﬁne the need to control Risk, Critical Items, and Key Characteristics. Also covered under these revisions is the need to possess a

better understanding of Conﬁguration and Risk Management. If you are able to understand both “the intent” and “the deﬁnition” of these key-additions to the AS9100 standard, you will know when you are making a right decision to add or delete processes and requirements within your operations. First, we must understand why changes were necessary to the AS9100C standard. The rational behind these

changes, as stated in AS9100C, is the revision of the standard to incorporate the requirements of ISO 9001:2008, which was updated as a result of the challenging times inherent in today’s global business environment. Globalization of business has led to great diversity in regional and national requirements. Over the years, we have evolved from an industrial nation to a service industry, and our expectations have complicated our objectives. Outsourcing has become a business practice for many manufacturers of aerospace, medical device and other products. Business models are no longer based on the development and manufacture of products, from start to completion. Rather, companies that were once manufacturers have become importers or “kitters.” Kitting is a business model that relies on parts that are imported from all over the world, that are assembled, often by a third-party located offshore in Central and Latin America or Asia Paciﬁc. The assembler will then afﬁ x the so-called manufacturer’s logo before the product is sold into the marketplace. All of these processes must be managed properly, which creates new and exciting challenges that require discipline and commonsense to properly deﬁ ne responsibility and authority without compromising customer, statutory and regulatory quality management system requirements. The following diagram illustrates the evolving business environment here in the United States.

NEW DEFINITIONS IN AS9100C The new definitions in AS9100C are expressed for good reason, they represent product or service specific objectives that have to be captured during the contract review and planning process.

TECH TIPS The rational behind these changes is the revision of the standard to incorporate the requirements of ISO 9001:2008, which was updated as a result of the challenging times inherent in today’s global business environment. 10 Aerospace Special Section | July 2011

Companies that were once manufacturers have become importers or “kitters”, a business model that relies on parts that are imported from all over the world, that are assembled, often by a third-party located offshore.

The new definitions in AS9100C are expressed for good reason, they represent product or service specific objectives that have to be captured during the contract review and planning process. www.qualitymag.com

We have gone from this to this business model 20th Century Business Model

21st Century Business Model

“Post-War Recovery Model”

The New Company Model

CEO Directors

Mentor Training

Not Adequately Trained To Function in the 21st Century

Journeyman

Have Academic Training Theory - Method

Executive Management New Gen X, Y Millennials

Executive Management Academic/Finance Training

Subcontractors Supply Technical Services

Managers Supervisor

New Gen X Y Millennials

Removed in the 21st Century

Acceptance/Safety/Trainee

A B C D E F G H I Sub-Contractors and Support Partners Have The Technical Skills

The evolving business environment. Source: Lean Quality Systems, Inc.

During the planning process each attribute is identiﬁed as a Conﬁguration Item, Risk, Special Requirements, Critical Item or any other Key Characteristic that must be treated as an objective. This means that the attribute is important, and important items are always in the light, on a traveler, or recorded in a speciﬁc report. Key deﬁnitions and meanings are: Conﬁguration Management (CM) – The sole purpose of conﬁguration management is to insure that a product maintains the same design, materials, composition or processing that as was originally intended by the owner from delivery through its entire lifecycle. Conﬁguration Items (CI) – Are used to identify speciﬁc attributes for conﬁguration management. Project Management – Plan and manage product realization in a structured and controlled manner, to meet requirements at acceptable risk, within resource and schedule constraints. Risk – An undesirable situation or circumstance that has both a likelihood of occurring and a potentially negative consequence. Special Requirements – Those requirements identiﬁed by the customer, or determined by the organization, which have high risk associated with them. Critical Items – Those items having signiﬁcant effect on the product realization and use of the product including safety, performance, form, ﬁt, function, producibility, service life.

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Key Characteristic – An attribute or feature whose variation has a signiﬁcant effect on product ﬁt, form, function, performance, service life or producibility, that requires speciﬁc actions for the purpose of controlling variation. It is important to note that special requirements and critical items, along with key characteristics, are interrelated. Additionally, any of the above that are identiﬁed by the customer statement of work, purchase order, or listed on a drawing are objectives that must be reported back, and captured and documented in the form of speciﬁc report or one on your traveling/work order.

APPLICABLE STATUTORY AND REGULATORY REQUIREMENTS The foreword to AS9100C states that, “to assure customer satisfaction, aviation, space and defense organizations must produce, and continually improve, safe, reliable products that meet or exceed customer and applicable statutory and regulatory requirements.” Regulatory authorities are commonly set up to enforce standards and safety, to oversee use of public goods and regulate commerce. Examples of regulatory agencies are the Interstate Commerce Commission and U.S. Food and Drug Administration in the United States, Ofcom in the United Kingdom, and the Telecom Regulatory Authority of India (TRAI) in India. Statutory law or statute law is written law (as opposed to oral or custom-

ary law) set down by a legislature, or other governing authority such as the executive branch of government, in response to a perceived need to clarify the functioning of government, improve civil order, to codify existing law or for an individual or company to obtain special treatment (Contrast common law). In addition to the statutes passed by the national or state legislature, lower authorities or municipalities may also disseminate administrative regulations or municipal ordinances that have the force of law. The process of creating these administrative decrees is generally classiﬁed as rulemaking. While these enactments are subordinate to the law of the whole state or nation, they are nonetheless a part of the body of a jurisdiction’s statutory law. Regulatory capture is a term used to refer to situations in which a government regulatory agency created to act in the public interest instead acts in favor of the commercial or special interests that dominate in the industry or sector it is charged with regulating. Manufacturing organizations have the challenge of purchasing products from suppliers throughout the world and at all levels of the supply chain. Suppliers have the challenge of delivering products to multiple customers having varying quality expectations and requirements. With the above education, you are now ready to jump into reviewing AS9100C changes, and applying them in a logical and practical way. In section 7, paragraph 7.1.4, the requirement identiﬁes the controls necessary to transfer work to other facilities or suppliers. Because you now understand today’s globalization and outsourcing, you are then responsible for whatever you outsource. As such, it makes sense for us to either establish a Traveling Work Order or have our supplier establish a Traveling Work Order that YOU approve with all the attributes (Key Characteristics, Conﬁguration items, acceptance requirements, etc.) in the instructions before the subcontractor starts work on our product. You may also have the subcontractor submit a First Run Sample for your approval before the Full Production Run.

July 2011 | Aerospace Special Section 11

AEROSPACE

| ADVANCES

Today’s aerospace engineering must take advantage of the biggest reason that AS9100C was revised, which as stated in the quality management system is “the globalization of the industry and the resulting diversity of regional and national requirements and expectations have complicated this objective.” In this scenario you used Globalization, Deﬁnitions, and Standard to make a logical decision about how to apply the new addition Section 7.1.4 to your company’s business practice. Note that your planning procedure should address how to handle “Control of Work Transfers.”

CONCLUSION Today’s aerospace engineering must take advantage of the biggest reason that AS9100C was revised, which as stated in the quality management system is “the globalization of the

industry and the resulting diversity of regional and national requirements and expectations have complicated this objective. Organizations have the challenge of purchasing products from suppliers throughout the world and at all levels of the supply chain.” Suppliers are challenged in delivering products and maintaining conﬁguration management relative to multiple customers who have varying quality requirements and expectations. Your job security lies in our ability to understand and implement both current and future quality management systems.

Under no circumstances should you underestimate the power you have to lead your company into a future of manufacturing practices that produce high quality products conforming to statutory, regulatory and customer requirements. M Joseph Sorrentino is president and CEO of Lean Quality Systems, Inc., Dana Point, Calif., a Veteran Owned Small Business. For more than 25 years, he has been instrumental in implementing successful quality management systems for commercial companies and government agencies throughout the United States. His clients have included The Boeing Company, Allied Signal/Honeywell, the United States Army Corp. of Engineers and the United States Navy. Sorrentino is the author of “Configuration Management: Implementation, Principles, and Applications for Manufacturing Industries” (CRC Press, 2008). He is recently introduced a training program based on the AS9100C revisions that is now available at from Amazon.com and at www. leanqualitysystems.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.

. . . creating a safer world

12 Aerospace Special Section | July 2011

Learn more at www.asnt.org or call the Technical Services Department at 800-222-2768

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Bringing Br ring gin ng the th he power powerr off LEDs LED Ds to o 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)

30,000-hour LED service life Electronic Intensity Stabilizer ensures consistent LED performance between charges Comes complete with smart AC and DC chargers, UV-absorbing spectacles, belt holster and padded carrying case

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Burnt O re: Broken ut Bulbs! Excess Filters! ive Heat!

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 9,000 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 4,500 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

Built-in fan keeps LEDs cool to maintain optimum light output Splash guard with integral particulate ﬁlter protects UV lenses and cooling fan from damage

Also includes lanyard, two replacement splash guards with integral particu-

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

ISO 9001:2008

For more information, call 1-800-274-8888 or visit www.spectroline.com

AEROSPACE

| ADVANCES

Eddy Current Inspection Sliding Probes

I

n the last eight months, there have been media reports of two commercial aircraft experiencing ruptures in their fuselages that required emergency landings. Thankfully, in these incidents the crews diverted safely without any injuries to anyone aboard. Though the failures apparently occurred for different reasons, cracks occurred in the Chem Mill pocket and in the Lap Splice in the second layer of the skin. Because the skin is thin in these areas, when it was weakened by cracking, ruptures occurred. Following these incidents, Service Bulletins (SB) were issued requiring eddy current inspections using Mid Frequency Eddy Current (MFEC) and sliding Dual

Frequency Eddy Current (DFEC) probe inspections. High and low frequency eddy current testing has been used as an NDT tool for many years, since the development of pencil, ring and spot probes in the 1960s and 1970s. It was not until the early 1980s that the development of sliding probes came into play. The ﬁrst sliding probes were used in low frequency, and then in the late 1980s, mid frequency was used for inspecting only in the ﬁrst layer. These LFEC and MFEC sliding probes were developed to slide over countersink fasteners and used to detect surface and subsurface ﬂaws. Countersink fasteners are generally installed on the outside of the air-

craft skins along lap joints, lap seams tear straps or areas on the exterior of the aircraft so as to not cause any drag or affect aerodynamics. Typically, cracks occur in the faying surfaces between the skin and second layer, or in some cases, in the third-layer structures inside the fastener holes. From there, they work their way along the grain boundary until they come to the next fastener hole, weakening the structure until failure occurs. One other technological improvement—in eddy current instruments themselves—was needed to permit the development and the use of sliding probes as a viable eddy current inspection method,. With the introduction of impedance-plane instruments, operators were able to adjust horizontal and vertical gain, phase angle, ﬁ lters and a host of other critical instrument parameters. Until the introduction of the impedanceplane instruments, most eddy current inspection was being done using meter/analog instruments. NDT technicians in the ﬁeld had to watch the needles swing back and forth, guessing what was a defect and what was just a geometry change affecting the eddy currents. Later, with both impedance-plane instrument and sliding probe technology available, the time was right for inspection improvements and time savings, enabling aircraft to return to service in less amount of time. Rohmann and Staveley (now Olympus NDT) pioneered the ﬁrst sliding probe technology in the 1980s. Major advancement in this area came while supporting McDonnell Douglas DC-9 and DC-10 SID programs at Long Beach, and with Boeing in Seattle. In 1988, an Aloha Airlines 737-200 experienced an explosive decompression and structural failure at about 24,000 feet due to metal fatigue in an upper cabin area, with about an 18-foot-long sec-

TECH TIPS When looking for cracks that are running in line with the fastener row, you can rotate the probe 90 degrees and scan in the same way as a fixed sliding probe. 14 Aerospace Special Section | July 2011

The Dual Frequency Eddy Current testing technique offers the ability to still use sliding probes to scan over countersink rivets and detect cracks, while filtering out noise from the varying rivet conditions caused by the alodine rivets.

NDT technicians armed with an eddy current instrument and a sliding probe will be able to inspect most aluminum skinned aircraft.

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tion of the fuselage separating from the aircraft. The crew was able to execute a successful emergency landing with a signiﬁcant portion of the upper fuselage missing. This event made metal fatigue in aging aircraft a major area of concern for civil aviation authorities. Sliding probes are so called because they move over fasteners in a sliding motion.

Sliding probes can be reﬂection, send-receiver, driver-pickup or transmit-receiver conﬁguration. Eddy currents are produced by a coil (driver) connected to the instrument’s oscillator. The signals received back in the probe are detected by a separate coil, called a pick-up. Sliding probes can come in two basic conﬁguration types—ﬁ xed or adjustable.

FIXED SLIDING PROBES Fixed sliding probes are typically used to detect cracks in the second layer, like lap splices. Lap spice thickness may be

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only .04 to 0.12 inches, depending on aircraft size and configuration. The frequency of these probes ranges from 1 kHz to 50 kHz. Fixed probes are typically used to detect cracks that are running along the fastener row along the 9 o’clock and 3 o’clock positions, in the same direction as the row of fasteners. Care must be taken to keep the sliding probe centered over the fasteners to get maximum flaw signal indications.

When a sliding probe passes over the countersink fasteners, an indication similar to Figure 1 is obtained. The liftoff is normally adjusted to conventional horizontal left direction on the eddy current instrument. The liftoff signal for sliding probes is not a straight line, like with other probes, but curves downward. It is important to remember that this test requires a reasonable comparison to a reference standard (Reference standards are samples simulating the area being inspected, with known defects, and are used to calibrate the instrument). Conditions like paint, fastener location and head size will have an effect on instrument signals and adjustment may be needed. As the sliding probe passes over fasteners, the screen signal movement begins from the null point (right side of the screen) and moves left

in the direction to X point. This will cause an arch-like indication, a mainly horizontal shift of the display along that distance as the eddy currents pass over the fastener and then move back to the null point. When the sliding probe passes over a fastener where there is a crack in the second layer, there will be an indication similar to Figure 2. The crack disrupts the eddy current ﬁeld and affects signal response. There is still an arch, but in addition, a hump or loop indication passes along the screen from the null point to X point and back to null point again. Fixed sliding probes can be used to detect cracks that are oriented at 90 degrees from the inspection direction in the second layer. Special care is required when doing this test, and it requires two passes over each row of fasteners with differently-oriented probes for the 12/6 o’clock and 3/9 o’clock orientations to complete the inspection. Adjustable sliding probes are better suited for these applications.

ADJUSTABLE SLIDING PROBES These probes can be adjusted by adding or removing spacers between the driver coil and the pick-up coil based on the fastener head size. As the fastener head size gets larger, the structure tends to get thicker, which will affect the depth of penetration of the generated eddy current field. Adjustable sliding probes come with clear acrylic spacers that allow the operator to see the probe center as it passes over the fasteners. The number of spacers used will vary as the structural thickness changes.

July 2011 | Aerospace Special Section 15

AEROSPACE

| ADVANCES

Adjustable sliding probes are used for ﬁnding subsurface cracks in thick multi-layer structures, like under wing skins where the thickness can be as much as 0.75 inches. This is about the maximum penetration depth for an eddy current ﬁeld in these types of structures.

The frequency range for these sliding probes is from 100 Hz to 50 kHz. Probes can be scanned along fasteners looking for cracks that are at the 12 and 6 or 9 and 3 o’clock positions in the countersink fastener hole. Typically when you scan at 90 degrees to the cracks, you will not get the loop like indications as ﬁ xed sliding probes, but a sharp narrow indication on the screen. A good fastener indication, as the sliding probe passes over the fasteners, is slightly similar to ﬁ xed probes.

16 Aerospace Special Section | July 2011

When comparing a good fastener to fasteners with crack indication, you will only see an increase in the vertical direction separation between good fasteners to ones with crack indication on the screen. The crack indication is similar in appearance to the indication of the good fasteners; this is do to the sliding probe scanning for cracks that are 90 degrees to the fastener and 90 degrees to the generated eddy current ﬁeld. See Figure 3. Note: Operating at 500 Hz to detect cracks in the third layer in a total stake up of .2 inches. When looking for cracks that are running in line with the fastener row, 9 and 3 o’clock positions, you can rotate the probe 90 degrees and scan in the same way as a ﬁ xed sliding probe. You will get similar indication for good fasteners. As the probe scans over fasteners where there is a crack, you get a similar, larger loop indication as a ﬁ xed sliding probe. See Figure 4. Note: Operating at 1 KHz inspecting for cracks that are under a total stackup of .125 inch. Aluminum rivets are the primary fastener used in manufactur-

ing aircraft. Rivets are a simple and inexpensive means to fasten aircraft skin to stringers, lap joints and other structures. Rivets are bucked or cold worked into the fastener hole and ﬁ ll the holes they are fastening. Rivets installed on commercial aircraft from the 1960s to the 1980s had an anodized ﬁ nish that created an electrical barrier between the rivet and the countersink holes in which they were installed. This helped the eddy currents ﬂow around the fastener and detect cracks in the rivet holes. From the late 1980s to 1995, alodine rivets were used as a replacement for

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anodized rivets. The primary reason for replacement was that the electrical barrier that was so beneﬁcial for eddy current testing had negative effects as well. When lighten strikes an aircraft, it generally follows the rows of rivets. When it comes across the electrical barrier between the rivet and the countersink holes, the result can be blown holes or blown rivet heads. The alodine ﬁ nish on the rivets allows it to have intimate contact with the aluminum skin. This contact becomes homogeneous and no electrical barrier occurs between the rivet and countersink hole, if installed correctly. This does not offer any area to allow the eddy current to ﬂow, and it becomes difﬁcult to use sliding probes to inspect rows of countersink rivets. The solution is to use Dual Frequency Eddy Current testing technique (DFEC). This offers the ability to still use sliding probes to scan over countersink rivets and detect cracks, while ﬁ ltering out noise from the varying rivet conditions caused by the alodine rivets. This requires the NDT technician to use an instrument with dual frequency capability and adjust the instrument to mix fastener signal variations and increase the sensitivity to the defect signal. Dual frequency is a technique that relies on adjusting the two frequencies, frequency 1 (F1) and 2 (F2) to see the rivet signals and the lower frequency, frequency 2 (F2) is set to see and detects the defects in the second layer. As the probe slides over the row of fasteners, the signal for either an alodine or anodized fastener, your signals will arch down off of the screen. Fasteners that are not making good contact in the countersink holes with defects will have a large loop indication. These large loop indications will trigger the instrument’s alarm gate. If the rivet is installed correctly, with good intimate contact between fastener and countersink hole, you will get a straight vertical indication. NDT technicians armed with an eddy current instrument and a sliding probe will be able to inspect most aluminum skinned aircraft. Even under the most difﬁcult conditions, with proper training and a good NDT back-

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ground to aid in their interpretation, they can consistently get the desired results to ensure that the aircraft structure does not have critical defects that will compromise the structures strength and integrity. M James Bittner is Senior Sales Engineer—Eddy Current and Bond Testing for Olympus NDT. He

has worked 25-plus years in Manufacturing Engineering Support, Quality Assurance and Technical Sales, primarily in the Aerospace industry. Most of his work has been in the support and development of eddy-current sensors and supporting standards, as well in the engineering and development of composite standards for the aircraft and aerospace industry. Phone: 509-736-2751

July 2011 | Aerospace Special Section 17

AEROSPACE

| ADVANCES

Halogen bulb

glare free view, with a white light source suitable for taking photos. For all of these reasons, LED white light source is well-suited to applications in aerospace, including the visual inspection of small parts, such as those used in aircraft turbine engine assemblies. The variable dimming feature cuts surface glare, allowing better defect veriﬁcation. Optical vision inspection systems beneﬁt from the high color rendition index, and constant color temperature, allowing for automated inspection techniques in the aerospace environment.

HISTORY

The History and Evolution of White Light Inspection Sources for Aerospace BY G REG FA LK

I

n the last 2 years, a new light source has ﬁ nally become commercially available that uses light emitting diodes (LEDs) as the white light source. These LED light sources have been around for 20 years in very low power forms, which were not suitable, or bright enough, for inspection and task lighting. Now we have LED light sources using multi-die technology, creating small point sources of light as high as 20 watts. These multi-die light sources can be put together in a focused array of only a few inches in diameter to create up to 100 watt light source with a luminous efﬁcacy of 130 lumens per watt, far surpassing older, incandescent light sources. The highest luminous efﬁcacy occurs when you drive these LED lights with a constant dc voltage, instead of AC voltage.

Equally important to the luminous efﬁcacy of LED light sources, these LED lamps can be dimmed using a pulsewidth modulation (PWM) technique, where the peak current remains constant as the duty cycle varies. This type of PWM dimming technique is carried out by an electronic integrated circuit light engine, which drives the LEDs directly. Using this constant peak current method of intensity control allows full range dimming, while keeping the color temperature constant, and hence, the color rendition index remains high. Also, it should be noted that the new LED white light source does not project any infra red heat energy, so these light sources are well suited for close up work with any type of task or sample illumination, and the constant color temperature dimming feature allows

In the early 1900s, bench-type task lights were powered by standard tungsten argon 12v or 120v bulbs. The brightness of these bulbs, even at close distances, was limited to approximately 1000 foot candles. The life of the bulb was approximately 1000 hours. These bulbs project infra-red heat, to some extent, making them frequently unsuitable for very-close-up work, or for biologic sample analysis under microscope or stereoscope. The luminous efﬁcacy of these bulbs is approximately 12 lumens per watt. It was not until the 1960s that a newer, more-efﬁcient and brighter light source, called the halogen lamp, became available. These lamps have a brightness of up to 6000 foot candles at close distances. The function of the halogen is to set up a reversible chemical reaction with the tungsten evaporating from the ﬁ lament. In ordinary incandescent lamps, this tungsten is mostly deposited on the bulb. The halogen cycle keeps the bulb clean and the light output remains almost constant throughout life. At moderate temperatures the halogen reacts with the evaporating tungsten, the halide formed being moved around in the inert gas ﬁ lling. At some time it will reach higher temperature regions, where it dissoci-

TECH TIPS LED light sources using multi-die technology create small point sources of light as high as 20 watts.

These LED lamps can be dimmed using a pulse-width modulation (PWM) tech18 Aerospace Special Section | July 2011

nique, where the peak current remains constant as the duty cycle varies.

The new LED white light source does not project any infra red heat energy, so these light sources are well

suited for close up work with any type of task or sample illumination, and the constant color temperature dimming feature allows glare free view, with a white light source suitable for taking photos. www.qualitymag.com

ates, releasing tungsten and freeing the halogen to repeat the process. In order for the reaction to operate, the overall bulb temperature must be higher than in conventional incandescent lamps. The bulb must be made of quartz or a high-melting-point glass. The high temperature of these halogen bulbs is an occupational work hazard especially for close-up work, where a person would get burned by touching the bulb envelope, or even the lamp shade that houses the bulb. In addition, these lamps project forward a large amount of infrared heat energy, forcing some users to insert an infra-red blocking ﬁlter on the front of the lamp. The luminous efﬁcacy of these halogen bulbs is approximately 24 lumens per watt, which is double the earlier tungsten argon bulb. It should be noted that the above examples of incandescent lamps can have their intensity controlled by varying the operating voltage to the bulb.

tion of the triac, which allowed the user to continuously vary the voltage and thus the intensity of the lamp. The main drawback of using variable voltage dimming is that as you dim the lamp , the color temperature changes, which causes the white light source to turn into a warmer orange color light source, which is not good if you are taking photos and lessens the color rendering index of the light source. M

LED lite

The early intensity controls were made with multi-tap transformers, giving discrete steps of intensity, usually limited to less than 10 steps. In the 1970s, a newer form of intensity control came out with the inven-

Scientific Instruments is one of the few companies today making LED white light sources for inspection task lamps, utilizing state of the art light engines with dc power source for maximum luminous efficacy, and universal input voltage for worldwide compatibility, along with full range PWM dimming adjustment for glare free viewing. This new LEDLITE can be viewed by visiting www.sciinst.com. Greg Falk is the engineering manager at Scientific Instruments in Skokie, IL. [email protected]

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July 2011 | Aerospace Special Section 19

AEROSPACE

| TECH

SHOWCASE

Digging Down Into Borescopes The newest technology offers users a host of choices to tackle the toughest of inspection and troubleshooting projects. BY DARRYL S ELA N D, ED I TOR I N CHI E F

B

orescopes are ﬂexible or rigid visual devices that are ﬁtted with an optical lens on one end and an object lens on the other. The object lens is responsible for delivering images back to the eyepiece. A relay tube enclosed by ﬁber-optic cables provides proper lighting to clearly view the object inside. Borescopes are often used for works that involve hard to access areas or as non destructive testing equipment. Considering the technique employed, these devices are real time and money savers. RF System Lab’s (www.rfsystemlab. us) VJ-ADVANCE is a highly-portable video borescope with joystick-controlled, four-way articulation. Features include a built-in 3.5” LCD display, onboard image and video capture capability, 2X digital zoom and easy one-hand operation. This video borescope is perfect for a wide range of industrial inspections. It is new to the market and very competitive on price and features. Advanced Inspection Technologies’ (AIT) (http://aitproducts.com) SnakeScope Video Borescope is an inspection camera designed for automotive, engineering, security, HVAC, plumbing,

RF System Lab VJ-ADVANCE

20 Aerospace Special Section | July 2011

AIT Snake-Scope Video Borescope

screen video. Available with synthetic sheathing, 3.8mm diameter, or tungsten sheathing, 4.1mm diameter, the EzyScope’s working length is 1000mm with forward view and 50° ﬁeld of view. Recognized for its superior functionality and ergonomics, EzyScope has a compact, stand-alone CCU (camera control unit) providing LED intensity control with both composite video output and USB 2.0 output for image capture. SCHOTT North America, Inc.’s (www.us.schott.com/lightingimaging) leached ﬁber bundles are very ﬂexible, coherent image guides. They are built by multiple draws of a high index core glass, with a lower index clad glass and an acid-soluble jacket glass. Leached Fiber Bundles are used primarily in endoscopes for medical or veterinary applications as well as in some industrial applications. Gradient Lens Corporation’s (http:// gradientlens.com) Hawkeye Flexible Video Borescopes are an ideal choice

construction and other applications. The new hand-held video borescope can inspect pipes, engines, process lines, behind walls, industrial piping, HVAC, ducts and other difﬁcult to reach areas up to a distance of 10 feet. Schoelly Imaging Inc.’s (www. schoellyimaging.com) EzyScope® Video Borescope with LED illumination is small and sturdy with a 3.8mm diameter probe offering two-way deﬂection and features integrated, high-power LED illumination and brilliant, fullGradient Lens Corporation Hawkeye Flexible Video Borescopes

Schoelly Imaging Inc. EzyScope® Video Borescope

for visual inspection when portability, and easy image capture, are key factors. These scope deliver 5-times higher image quality than ﬁber optic borescopes. Fully portable, they are either 2- or 4-way articulating, and come complete with video monitor and light source, all in one easy-to-use device. Hawkeye Pro Flexible Videoscopes are either 4 mm or 6 mm in diameter, and have ﬂexible tungsten sheaths. They are available in lengths of 1.5 and 3.0 meters. Custom lengths up to 6.0 meters are available upon request.

www.qualitymag.com

AEROSPACE

| CASE

STUDY

military, commercial, industrial and the entertainment market. In its 57,000-square-foot facility, Coast has churned out both designs and fabrications, enabling the manufacturer to control the prompt delivery of end products. Coast applies years of combined experience to small and large fabrication of ground support, proof load and Coast Aerospace Manufacturing functional testing, SE utilized portable coordinate and GSE tool refurmeasuring machines (CMMs) for bishment, precision dimensional control applications aerospace machining of within a large measurement volﬂight hardware, major ume. Source: Hexagon Metrology assemblies and a variety of services for systems, hydraulic and pneumatic applications and electronics.

CREATING AGILITY

Lending a Hand with

Precise Tooling Hexagon Metrology outsourced critical expertise and machinery to help an aerospace part manufacturer augment its inspection and measurement requirements.

M

anufacturing executives in smallto-mid-size enterprises face a variety of operational hurdles in this tenuous economy, such as ﬂat budgets, peaks and valleys of workﬂow, quality demands, lack of employee expertise in speciﬁc disciplines and keeping up with technical training. Whether production is boon or bane, survival of the ﬁttest depends on business creativity and customization. With a realistic assessment of the value within the organization and by prioritizing people, processes and performance to consistently render a highquality product, a manufacturer can

tactically size up challenges and reach for practical solutions when a new opportunity appears, or operational demands exceed in-house talent. Coast Aerospace Manufacturing—with its resourceful approach to building and sustaining an agile enterprise—is one such company. Based in Placentia, CA, Coast Aerospace is a turnkey engineering, design and build-to-print manufacturer. The certiﬁed ISO9001:2000/AS9100 company specializes in tool design, engineering, machining and fabrication. It runs the gamut of tier-one original equipment manufacturers (OEMs) in aerospace,

Outsourcing is not a novel concept to original equipment manufacturers (OEMs) and the sub-tiers of contract manufacturers serving them. In the quality control arena, the lack of trained and qualiﬁed metrologists continues to be an industry-wide concern. By partnering with Hexagon Metrology Services (HMS), Coast Aerospace augments its inspection and measurement requirements for ﬁeld operations at customer sites or in-house capacity when it is needed. To maintain maximum productivity on the shop ﬂoor, the company’s measurement and inspection department must run at full tilt with no disruptions. Coast employs three metrologists trained in 3-D measurement technologies and the use of high-precision Leica laser trackers. The portable coordinate measuring machines (CMMs) are utilized for dimensional control applications within a large measurement volume, such as tooling, part mating, assembly and other inspection operations. The technicians use the laser trackers on the shop ﬂoor to acquire 3-D data, and evaluate and set critical features on parts, molds and tooling.

BENEFITS Coast’s human resource needs continued to grow, and merging expertise was critical. At the height of the project, 10 Hexagon specialists were brought into the fold.

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Hexagon Metrology employs metrology experts who can quickly familiarize themselves with a client’s operations.

Hexagon’s supplementing of Coast Aerospace Manufacturing’s staff has essentially doubled Coast’s output.

July 2011 | Aerospace Special Section 21

AEROSPACE

| CASE

With 15 to 20% of its business focused on repairing parts and tooling, Coast also wants to keep its two Brown & Sharpe CMMs at operational capacity. The machines have measuring volumes of 1,500 millimeters by 3,000 millimeters by 1,000 millimeters and 400 by 500 by 400 millimeters, respectively. Well-versed in the use of PCDMIS inspection software, the company’s quality control team provides services for measurement, quality control, digitizing and reverse engineering. Leveraging in-house metrology capabilities to ensure customer parts, ﬁ xtures and tooling are up to par with technical speciﬁcations translates into a proﬁt center for Coast’s business. Coast’s ability to supplement its staff has essentially doubled its output. One of the advantages of working with a large OEM is its breadth of worldwide application expertise and latest-generation metrology equipment.

STUDY

Hexagon Metrology serves more than 125 distinct industries with its products and full range of services, includ-

ing temporary to full-time stafﬁ ng contracts, tailored training programs, system integration, custom program-

Coast Aerospace Manufacturing was tasked with fabricating new, large-scale assembly tools, as well as refurbishing older tools for a large cargo aircraft. Source: Hexagon metrology

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22 Aerospace Special Section | July 2011

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ming, contract inspection and reverse engineering. Beyond the typical product support services, the company is active in deploying in-house expertise to make a customer’s operations more effective and productive. Using a small-scale line of attack, Coast Aerospace has effectively tapped into Hexagon’s experts for a variety of tasks from precision inspection to the manufacture, veriﬁcation and repair of tooling. More importantly, the employment of these resources has enabled Coast to build a quick response mechanism for its customer’s on-site needs. Instead of pulling crucial resources, master technicians from Hexagon can be deployed when necessary.

FINDING THE EXPERTISE OVERLAP Pooling expertise on a small scale was a launching pad for Coast to realize that it could go bigger if the opportunity knocked on its door—and it did.

One of Coast’s aerospace customers approached it with a highly time-sensitive project with incremental deadlines to keep assembly operations on track. Coast’s piece of the project entailed fabricating new, large-scale assembly tools, as well as refurbishing older tools for a large cargo aircraft. The responsibility of bringing six large tools up to quality-assurance-ready buy-off in less than three months was formidable, leaving roughly ﬁve weeks per overhaul. The overall project spanned more than one year and involved several hundred tooling, engineering, design and inspection personnel. Coast could manage the project, but needed more capacity; more skilled tooling people; more laser tracking systems and additional, hard-to-ﬁnd inspection experts. Louis Ponce, president of Coast Aerospace Manufacturing, reached out to a proven partner, but this time on a much larger scale.

Hardness testing the handy way!

Coast Aerospace won the contract as a third party and enlisted the support of Hexagon Metrology Services. Coast’s project manager would run the project on-site. “In this situation, we needed more support people to join our seven teams working around the clock,” Ponce says. “I was looking for fresh help, but they had to be top quality experts who can come up-to-speed very fast. One of the main beneﬁts of working with Hexagon Metrology is their precision centers are located in close proximity to major manufacturing centers. As a leading OEM of metrology solutions, their equipment is on-hand for immediate access and their people are trained on the equipment for application speciﬁc tasks.” Hexagon Metrology Inc. 847-931-0100 www.HexagonMetrology.us

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The one-hand EQUOTIP hardness tester! It’s innovative charge-release mechanism enhances usability and speeds up measurements. Proceq‘s Piccolo offers: sSTANDARDIZEDMEASUREMENTS$).!34-! sTOPTESTINGACCURACYBEYONDTHESTANDARDS sAUTOMATICCORRECTIONFORTHEIMPACTDIRECTION sCONVERTSTOALLCOMMONHARDNESSSCALES sSTATISTICSAVERAGE STANDARDDEVIATION MINMAX RANGE sBIDIRECTIONALCOMMUNICATIONVIA53"AND0)##/,).+SOFTWARE Proceq USA, Inc. #ORPORATION$RIVE !LIQUIPPA 0! 4EL &AX [email protected]

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July 2011 | Aerospace Special Section 23

AEROSPACE

| PRODUCTS

PIEZOELECTRIC SIGNAL CONDITIONER

BLENDING SCOPE

Meggitt Sensing Systems Endevco® model 133 is a three-channel general purpose piezoelectric signal conditioner with a wide bandwidth of 100 KHz (-3 dB corner), designed to condition accelerometer output signals within modal and structural analysis, NVH, automotive and aerospace testing and general in-laboratory applications. Featuring an industry standard bench mount configuration, the Endevco model 133 offers a standard RS232 serial interface and supports both ISOTRON® (IEPE) and charge output piezoelectric accelerometers with either manual or computer programmable configurations. Operation and programming of the Endevco model 133 is achieved via the LED illuminated front panel with adjustable gain range of 0 to 1000. A flexible setup allows the user to match a wide range of sensor sensitivities, with output scaling per Engineering Units in mV/G, while three LED’s serve as built-in fault status indicators for open/short per channel at ISOTRON® inputs. MEGGITT SENSING SYSTEMS WWW.MEGGITTSENSINGSYSTEMS.COM

The Richard WOLF Blending Scope is built like a traditional borescope. Its shaft is inserted through one of the standard borescope ports with the tool extended. To engage the blending tip, just position it at about 90°. A motor drives the lip up to several thousand rpm. The blending process is observed through a high resolution optical lens system either by direct vision through the eyepiece (Rich-

FLEXIBLE VIDEO BORESCOPE The new Hawkeye Flexible Video Borescopes are the perfect choice for visual inspection when portability, and easy image capture, are key factors. These scope deliver 5X higher image quality than fiber optic borescopes. Fully portable, they are either 2- or 4-way articulating, and come complete with video monitor and light source, all in one easy-to-use device. Hawkeye Pro Flexible Videoscopes are either 4 mm or 6 mm in diameter, and have flexible tungsten sheaths. They are available in lengths of 1.5 and 3.0 meters. Custom lengths up to 6.0 meters are available upon request. Manufacturers of mission-critical parts, especially in transportation sectors, value the speed and accuracy of Hawkeye Borescope visual inspection. Aircraft part manufacturers, for example, can quickly inspect oil coolers, turbine blades, landing gear, hydraulic parts, and a variety of other cast and machined parts. Hawkeye Video Borescope features include: • Lever-controlled 2 or 4-way articulation • Integrated monitor and light source • Built-in USB connection and SD Memory Slot • Miniature CMOS camera • Fiber optic illumination GRADIENT LENS • 800-536-0790 • WWW.GRADIENTLENS.COM

24 Aerospace Special Section | July 2011

ard WOLF standard) or via any standard industrial video camera system. A wide range of tools for cut-ting, grinding, polishing and brushing are available in different lengths and can be fitted to the unique patented miniature drive tool. The Richard WOLF Blending Scope is an all-rigid design which enables the user to exert the working force directly on the damaged object and to “feel” the blending process. No loss occurs from flexible parts. For optimum vision the optical system can be moved within the shah. Tools can be changed within a few seconds without affecting the optical system, and are secured in a positive manner against loss in the engine. The Richard WOLF Blending Scope offers a variety of technical advantages: • high precision handling • ideal field of view • different tools for optimum efficiency • simple tool change • working angle adjustablestable for optimum access • simple way of measuring damage and blending result • observation position adjustable for different tool lengths • compatible to all standard borescope equipment RICHARD WOLF 847-913-1113 EXT 6208 WWW.RICHARDWOLFUSE.COM/INDUSTRIAL

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AEROSPACE

| BUSINESS

CARDS

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PAGE

PHONE

WEB ADDRESS

American Society for Nondestructive Testing

12AS

(800) 222-2768

www.asnt.org

Applied Test Systems Inc.

19AS

(724) 283-1212

www.atspa.com

BSI

23AS

(888) 429-6178

www.bsiamerica.com/9100transition

Carestream Health

3AS

Easy-Metric

17AS

(312) 428-6619

www.easymetric.com

Epsilon Technology Corp.

8AS

(307) 733-8360

www.epsilontech.com

Gradient Lens Inc.

5AS

(800) 536-0790

www.gradientlens.com

Machida

8AS

(845) 365-0600

www.machidascope.com

NDT Systems

9AS

(714) 893-2438

www.ndtsystems.com

Olympus NDT

IFCAS

(800) 225-8330

www.olympus-ims.com

Proceq USA, Inc.

23AS

(724) 512-0330

www.proceq-usa.com

Spectronics Corp.

13AS

(800) 274-8888

www.spectroline.com

Test Equipment Distributors LLC

22AS

(800) 962-1788

www.tedndt.com

Verimation Technology

19AS

(800) 521-5245

www.verimation.com

Yxlon International

BCAS

(330) 798-4834

www.yxlon.com

www.ndt.carestream.com

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

www.qualitymag.com

July 2011 | Aerospace Special Section 25

Y.Multiplex Truly all-purpose

Q Highly dynamic radioscopy (HDR) and CT in one universal X-ray inspection system Q Automatic defect recognition (ADR) Q Programmable inspection workﬂow for CT and radioscopy Q Depiction of CT tomograms directly in the system software YXLON A division of Comet Technologies USA Akron 3400 Gilchrist Road Akron, OH 44260-1221, USA T: +1 330 798 4800 www.yxlon.com

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