Quality June 2011

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JUNE 2011, VOLUME 50/NUMBER 6

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TABLE OF

CONTENTS QUALITY MAGAZINE

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JUNE 2011

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VOLUME 50

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NUMBER 6

DEPARTMENTS 6

FROM THE EDITOR

No Compromise 8

INDUSTRY NEWS

Source: InfinityQS

85% of U.S. Consumers Want to Buy an Electric Vehicle

34 FEATURES 50 YEARS OF QUALITY

Nissan Leaf Declared 2011 World Car of the Year Spending and Hiring on the Rise for Midsized Manufacturers 14 FACE OF QUALITY

20 FROM LUXURY TO STAPLE: CMMS Once considered a luxury for ensuring quality control, coordinate measuring machines (CMMs) are now a staple in both large manufacturing plants and small job shops. This month Quality takes a look back at technology that was developed in the early 1960s.

QUALITY MEASUREMENT

24 MULTISENSOR METROLOGY COMES OF AGE Advances in capability and software make multisensory metrology mainstream.

Manage the Human Side of Quality Improvement 16 OTHER DIMENSIONS

Calibration Mistakes: Thread Plug Gages 18 QUALITY 101

Connecting the Dots of Color Measurement

QUALITY TEST & INSPECTION

28 ADVANCED OPTICAL TECHNOLOGY OPENS NEW DOORS Recent advancements in optical technologies are enabling manufacturers to perform dimensional measurements on more kinds of parts, more quickly and more accurately.

QUALITY SOFTWARE & ANALYSIS

34 ADVANCES IN MOBILE DATA COLLECTION EXTEND QUALITY’S REACH Today’s portable devices allow quality analysis technologies to extend beyond the plant floor for complete traceability and enhanced collaboration.

42 CASE STUDY

Lofty Goals Demand Precise Positioning Saving Money with Comparative Gages 50 QUALITY PRODUCTS 55 CLASSIFIEDS 56 ADVERTISING INDEX

QUALITY MANAGEMENT

38 STRATEGIC BUSINESS IMPROVEMENT IN THE NEW ECONOMY The future is recognition and cultural acceptance of accelerated, technology-driven, sustainable strategic improvement with unlimited possibilities, and unlimited competitive rewards for success.

NEXT MONTH State of the Profession Study Measurement, Test & Inspection Guide Registrar/Certification Guide Software Selector Guide

JUNE 2011, VOLUME 50/NUMBER 6 WWW.QUALITYMAG.COM

ABOUT THE COVER

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The reality of multisensor metrology today is best described as hardware and software capability and inspection technique, and not a specific type of metrology platform. In fact, various types of convergence mean multisensory technology has made different types of metrology platforms more similar—and more capable—than ever. Source: Hexagon Metrology

QUALITY | June 2011

www.qualitymag.com

Y OU R

A DVA NTA G E

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S TA R R E T T

IN N OVAT ION

A FRESH

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

AVT Cameras Help Locate Air France Crash Wreckage Nearly two years after the mysterious crash of Air France ﬂight 447 between Rio de Janeiro and Paris, it was a sensation when the French investigation authorities announced earlier this month they had ﬁnally located the wreckage of the aircraft lying 12,800 feet deep in the Atlantic Ocean.

Eddy Current Testing: Its Many Beneﬁts and Applications June 14, 2:00 p.m. ET Measurement 101: Essential Knowledge June 16, 2:00 p.m. ET

Off-Topic Quality: Building a Reliable Source of Information A $230 billion manufacturer not only acquired and implemented a master data management (MDM) system, but sought to change the company’s operational strategy to ensure that critical product data was accurate, relevant and actionable. The Performance Curve of a Device A little-know yet important subject, the performance curve of a device is a concept that allows us to evaluate a device’s behavior in several points along the engineering speciﬁcation range. Through the results of this ﬁeld of study, it is possible to determine the probability of acceptance of each measured part of the studied device.

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• 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 | June 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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Look closer.

Optically measure complex shafts in seconds. Diameter, length, geometry and form. Automatically. To microns. ■

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With Hommel-Etamic, your production quality never had a greater chance for improvement. For measurement reliability, uncompromised precision, and worldwide technical support, call on Hommel-Etamic.

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Precision is Our Business.

FROM THE EDITOR

NO COMPROMISE NAVIGATE THE CULTURE SHIFT TO NO-COMPROMISE LEADERSHIP.

L GILLIAN CAMPBELL

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

eadership is all about being able to influence others and make an effective impact. In these challenging times, that can be difficult to accomplish. At this year’s Quality Conference, held April 11-13, in Charlotte, NC, in conjunction with the University of North Carolina-Charlotte and The Charlotte Research Institute, Neil Ducoff, founder and CEO of Strategies (Centerbrook, CT), and author of “NoCompromise Leadership,” gave a keynote address on this topic. No-compromise leadership is all about the thinking, behavior and accountability that support all leadership results and outcomes. Joined together, these two simple words immediately establish a higher standard of leadership thinking and behavior. They provide a powerful internal compass that keeps you and your company steadfastly on course. By design, no compromise cuts through the myriad excuses, emotional blockages and procrastination that silently infect leadership performance. During his presentation, Ducoff provided the audience with tips on navigating the murky leadership waters: 1. Clarity. Have absolute clarity on where you are taking your company, department, etc. 2. Values. If you want them, live them. If values are compromised within the company, the changes can have a tidal wave effect. 3. Accountability. Get it done. A leader is defined by his resolve, tenacity and courage to get things done. 4. Transparent. No excuses when you compromise. Own it.

5. Culture. Don’t destroy from within. Hiring the wrong person can wreck havoc. 6. Unity. Don’t be dictorial and inflexible. Stress that we’re in it together. 7. Focus. Don’t stay in your office. The action is where your people are. If you’re so busy doing the work, how can you lead? You have to be with your people. 8. Strategic. Manage what’s on your plate. If you have a monkey on your back, it’s going to stomp you into the ground. If you’re the answer man or woman, employees don’t have to think—or make mistakes. 9. Resolute. Be tenacious and courageous. 10. Inspire. You can’t lead without passion. Ducoff addressed that no-compromise leadership isn’t easy—even for him. He said many cultures never succeed; company culture can crumble under the weight of compromise radiating from leadership; and compromise can be a pure drag. Are you ready take on no-compromise leadership? Share your challenges and 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.

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QUALITY | June 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

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JULY 11 LEADING WITH LEAN WORKSHOP 2011 Juran Institute, Clearwater, FL (800) 338-7726 www.juran.com/downloads/LeadingwithLeanWorkshop_2011.pdf 25-29 CMSC, Phoenix Coordinate Metrology Society, (888) 320-7011, www.cmsc.org 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 OCTOBER 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

ASSOCIATION NEWS THE COORDINATE METROLOGY SOCIETY (CMS, Benbrook, TX) announced Trevor Toman as the chair of the organization’s newly formed academic subcommittee. Toman will serve as a liaison with key education institutions to forge long-term knowledge-sharing and working relationships. Toman has worked in the manufacturing industry for more than 30 years, with extensive experience in the calibration and measurement disciplines. THE CANADIAN INSTITUTE FOR NDE (CINDE, Hamilton, Ontario, Canada) has promoted Larry Cote CET, CLS, CMRP to president and CEO, reporting to the chairman of the board. In his Cote position, Cote will work closely with the executive committee and the board to pursue the goals set out in the CINDE strategic plan. THE AUTOMOTIVE INDUSTRY ACTION GROUP (AIAG) has appointed two new directors. Stuart Harrison, vice president of Eaton Corp., and Jeff Spicuzzi, director of Lear Corp., are now part of AIAG’s board of directors.

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BUSINESS NEWS | COMING EVENTS | PEOPLE NEWS | MERGERS

85% OF U.S. CONSUMERS WANT TO BUY AN ELECTRIC VEHICLE BOULDER, CO—Plug-in electric vehicles may just be entering the market, but most U.S. consumers are ready to buy them. E Source recently analyzed data from the Nielsen Energy Survey and found that 85% of U.S. consumers say they would purchase a battery-driven car either right away (3%), when their current car needed replacement (57%), or when the technology is proven and it becomes more mainstream (25%). The caveat is that consumers strongly prefer (58%) plug-in hybrid electric (PHEV) versions such as the Chevrolet Volt. PHEVs have greater range than electric-only cars such as the Nissan Leaf, and 8% of consumers prefer them. “We are seeing a substantial willingness for drivers to move to plug-in electric vehicles, but only if the manufacturers can provide the easy extended range of travel that Americans are used to,” says Bill LeBlanc, senior advisor at E Source. E Source also reports that younger drivers are more willing than older drivers to purchase the electric-only cars, and people who describe themselves as liberals are similarly more inclined to desire the all-electric cars than those classified as conservatives. “We see that all ages and all political mindsets like the plug-in hybrid vehicles equally,” says LeBlanc. “But when it comes to the allelectric car, it appears to be seen as more of a ‘green’ purchase, rather than as a practical upgrade to a more-efficient vehicle.” Another factor that E Source looked at was how far people drive each day and how that affects their desires for for plug in electric vehicles. Daily driving habits do not seem to affect desire for the allelectric vehicle; however, desire for the

PHEV grows as people spend more time in their cars. “Overall, the survey supports the existence of a huge untapped market for electric vehicles that can be charged at night at home. People seem very ready to move to the next generation of cars and dramatically decrease the frequency of their visits to the gas station,” reports LeBlanc.

NISSAN LEAF DECLARED 2011 WORLD CAR OF THE YEAR NEW YORK CITY—At a press conference hosted by Bridgestone Corp. and the New York International Auto Show, the Nissan Leaf was declared the 2011 World Car of the Year. The Nissan Leaf was chosen from an initial entry list of 39 new vehicles from throughout the world, then a short list of 10, then three finalists: the Nissan Leaf, the Audi A8 and the BMW 5 Series. The Leaf is a five-seater, five-door hatchback and the jurors said it is the world’s first, purpose-built, massproduced electric car. The Leaf has lithium-ion battery modules and electric motors that generate 108 horsepower and 206 pounds feet of torque, propelling the hatch from zero to 60 miles-per-hour in 11.5 seconds and a top speed of 90 miles per hour. It has a range of more than 100 miles on a full charge, Nissan says, and takes around eight hours to recharge using 220-240 volt power supply and produces zero tailpipe emissions. Its low center of gravity produced sharp turn-in with almost no body roll and no understeer. Previous World Car of the Year winners were the Volkswagen Polo in 2010, Volkswagen Golf in 2009, the Mazda2/ Mazda Demio in 2008, the Lexus LS460 in 2007, the BMW 3-Series in 2006 and the Audi A6 in 2005.

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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SPENDING AND HIRING ON THE RISE FOR MIDSIZED MANUFACTURERS, BUT COSTS CAUSE CONCERN CHICAGO—Prime Advantage, a buying consortium for midsized manufacturers, announced the results of its seventh Prime Advantage Group Outlook (GO) Survey, revealing the top economic concerns of small and midsized North American manufacturers for 2011. The survey results show companies are even more confident compared to six months ago about economic growth for U.S. manufacturing in 2011. Moreover, these results support the latest findings in the Prime Advantage Group CFO Survey, which showed optimistic expectations for revenue growth, hiring and capital spending despite growing concerns over rising costs. “Our members, who represent a diverse cross section of manufacturing industries, are experiencing stronger growth and plan to invest back in their businesses, whether through capital expenditures or hiring more employees,” says Louise O’Sullivan, founder and CEO of Prime Advantage. “What’s unique and challenging about this rebound is the rate at which firms must address pricing inflation in both raw materials and components. As a buying group, with leveraged programs based on group volume, our members are positioned a little ahead of the curve and our job is to make sure we help them maintain that advantage.” The highlights of the findings include: • Seventy-two percent of the small and midsized manufacturing professionals who took the survey report that their companies expect revenue increases in 2011, with 24% expecting increases of more than 10%. • The top three cost pressures for the next six months are: the cost of raw materials (with 96% including it in the top three concerns), followed by inflation (52%) and healthcare (37%). • Sixty-five percent plan capital expenditures for manufacturing equipment and tools in 2011, greatly triggered by available federal tax credits. • More than 80% said their companies were making changes toward developing more sustainable products, largely driven by customer requirements and compliance regulations. • While 40% of respondents that source products from off-shore

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NEWS MARLIN STEEL WIRE (Baltimore, MD) has announced plans to expand its manufacturing floor space in Baltimore City, after its best first quarter in history, four years of record profits and steady revenue increases, and a surge in export demand for custom wire baskets, wire forms and sheet metal fabrications such as housings and consoles. Marlin Wire has brought on adjacent manufacturing space to maximize efficiencies and permit manageable growth. CURTISS-WRIGHT CORP. (Parsippany, NJ), through its Motion Control segment, has renewed its long-term agreement with Boeing Commercial Airplanes. The agreement extends the current contract and gives CurtissWright exclusive rights to manufacture numerous products for Boeing production airplanes, including the 737 and 767 trailing edge flap actuators, 747-8 leading edge flap actuators, 777 flap position gearboxes, 767 and 777 cargo door actuators, 747-8, 767 and 777 cargo hold smoke detectors and various flight control and pilot control position sensors. DGI SUPPLY, a DoALL company (Wheeling, IL) has signed a letter of intent to purchase all outstanding shares of Midwest Industrial Tools (MIT, Omaha, NE). Allan Chartier, the current president and CEO of MIT, will remain with the company through the transition. TOOLING U (Cleveland, OH), the leading developer of online manufacturing training, has relocated its headquarters to Tyler Village—one of Cleveland’s largest-ever downtown redevelopment projects. Located six miles from Tooling U’s previous office, Tyler Village, a former industrial complex and now a thriving, mixed-use business complex, fit the needs of the growing company. RENISHAW PLC (Gloucestershire, UK) has received a Queen’s award for Enterprise 2011 in the innovations category, the company’s 14th Queen’s Award since its formation in 1973, and its fifth in eight years.

BUSINESS NEWS This award has been granted for the development of the TRS2 laserbased noncontact broken tool detection system, which is used for detecting broken or missing cutting tools on computer numerically controlled (CNC) machining centers. HERRMANN ULTRASCHALL (Bartlett, IL) celebrates its 50th anniversary this year. The ultrasonics company will celebrate its anniversary on November 3, 2011, and technology days with seminars on November 3-4, 2011. The Herrmann Group says it is proud of its growth and achievements and foresees future job growth at the company. BEAVER AEROSPACE & DEFENSE (Liviona, MI), a designer and manufacturer of actuation technologies, has received a 2010 Boeing Performance Excellence Award. The Boeing Co. issues the award annually to recognize suppliers who have achieved superior performance. Beaver maintained a gold composite performance rating for each month of the 12-month performance period, from Oct. 1, 2009 to Sept. 30, 2010. Metrology and measurement device manufacturer BLUM-NOVOTEST (Willich, Germany) is part of a team that has won a Chairman’s Award from BAE Systems. BAE Systems has recognized a team at its Samlesbury plant that includes BAE Systems and Blum-Novotest employees. Blum-Novotest helped reduce cycle times by more than 40% on production components for the Typhoon aircraft. RAYTHEON CO. (Tewsbury, MA) was awarded a $128.5 million contract to provide engineering services for the Patriot Air and Missile Defense System. Issued by the U.S. Army Aviation and Missile Command, Redstone Arsenal, AL, the contract calls for Raytheon to continue to provide the latest upgrades and system capabilities through systems analysis, software and hardware engineering, and testing and logistics support to both U.S. and international Patriot customers.

vendors are planning to bring sourcing back to North America in the near future, indicating a rebalancing in sourcing strategy, another 60% are planning to add more offshore vendors.

GM TO INVEST $100 MILLION, ADD 30 JOBS IN ROCHESTER, NY ROCHESTER, NY—General Motors will invest $100 million to add 30 jobs and purchase tooling and equipment to make future automotive components at its GM Components Holdings (GMCH) Rochester operations. “This investment in our manufacturing operations will enable us to produce a new generation of fuel-efficient small block car and truck engines,” says Cathy Clegg, GM vice president of Labor Relations. “The Gen V small block engine family will have unprecedented fuel efficiency, and GMCH Rochester Operations will play a key role in helping us deliver these efficient engines to our customers.” Four product lines will be enhanced: the integrated air module; a new high-pressure fuel rail; a new lifter oil manifold assembly; and a new direct

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injection injector. These parts will be shipped to GM Powertrain plants in Tonawanda, NY, St. Catharines, Ontario, Canada and Ramos Arizpe, Mexico. “This investment stems from teamwork with New York’s Empire State Development Corp., Rochester Gas and Electric and a new agreement with the UAW,” Clegg says. “Through these types of successful partnerships, we’re competitively keeping this work in the United States and maintaining jobs right here in Rochester.” The 30 new jobs will be added to an existing workforce of 826 hourly and salaried employees at the GMCH Rochester operations facility.

CHRYSLER GROUP SUPPORTS ENGINEERING PROGRAMS AUBURN HILLS, MI—The deans of Abet-accredited Historically Black Colleges and Universities (HBCU)—in conjunction with the corporate-academic alliance members of Advancing Minorities’ Interest in Engineering (AMIE)—have selected Chrysler Group LLC as a Top Supporter of

HBCU and other minority-serving institutions. Chrysler joins a distinguished list of corporate and governmental leaders engaged in supporting the development and recruitment of talent students pursuing technical careers at the nation’s minority-serving institutions. This ninth annual survey of education leaders was conducted by U.S. Black Engineer & Information Technology magazine. In completing the annual survey, the deans considered a corporate or governmental candidate’s support for infrastructure modernization and enhancement, research, participation on advisory councils, faculty development opportunities, scholarships, student projects, co-ops and career opportunities.

TOYOTA ANNOUNCES FINALISTS IN 100 CARS FOR GOOD PROGRAM TORRANCE, CA—Toyota announced the 500 nonprofit organizations selected as finalists in the 100 Cars for Good program, which will award 100 vehicles

throughout the course of 100 days to 100 nonprofit organizations based on votes from the public. Toyota’s 100 Cars for Good initiative engages the public to determine the 100 organizations to receive a Toyota vehicle for use in the community. The 500 finalists, selected from a pool of applications submitted via Toyota’s Facebook page from March 7-21, 2011, were chosen by an independent panel of judges who are experts in the fields of philanthropy and corporate social responsibility. The finalists represent nonprofit organizations servicing the community across a broad range of categories including animal welfare, arts, education, environment, health, safety and human services. Finalists will create an online profile, which may include a video showcasing how the organization plans to use a new Toyota vehicle to do good in their local communities. Started on May 9, public voting takes place for 100 consecutive days, with five organizations profiled on Toyota’s Facebook page each day. The public may vote for

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June 2011 | QUALITY

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NEWS the charity they feel is most deserving based on the created profiles. A vehicle will be awarded daily through August 16 for a total of 100 vehicles. Voters may place one vote per day, each day, throughout the course of the program. Winning organizations can choose from the following vehicles: Toyota Prius, Tacoma, Tundra, Highlander Hybrid, Sienna or Sienna Mobility. With each vehicle, Toyota Financial Services will provide a sixyear, 100,000 mile service agreement to help provide extended protection from mechanical breakdowns beyond the vehicle warranty.

BUSINESS CONDITIONS REPORT: APRIL 2011 CLEVELAND, OH—According to the April 2011 Precision Metalforming Association (PMA) Business Conditions Report, metalforming companies anticipate a softening in business conditions during the next three months. Conducted monthly, the report is an economic indicator for manufacturing, sampling 131 met-

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PEOPLE Ferromatik Milacron India Ltd. (FMIL, Gujarat, India), an injection molding machine manufacturer, has promoted SHIRISH DIVGI to the role of COO and VINOD BHALAVAT to the role of CFO of FMIL, a division of Milacron Plastics Machinery. The promotions correspond with the recent retirement of former FMIL president N.K. Balgi.

Divgi MARK MOHR has been appointed to the role of president, DMG/Mori Seiki USA (Chicago). In his new role at the Hoffman Estates, IL, headquarters, Mohr will oversee operations of all technical centers across the country to optimize the value of the DMG and Mori Seiki collaboration in America.

Bhalavat

JOHN PURVIS has been named president and CEO of AME Unmanned Air Systems (formerly Mohr AeroMech Engineering Inc., San Luis Obispo, CA). He succeeds Jay McConville, who will now serve as AME UAS’s chairman of the board and as an executive vice president at ChandlerMay.

alforming companies in the United States and Canada. The April report shows that 40% of participants forecast an improvement in economic activity during the next three months (down from 49% in March), 45% predict that activity will remain unchanged (compared to 46% last month) and 15% report that activity will decline (up from only 5% in March). Metalforming companies also expect a drop in incoming orders over

the next three months, with 20% predicting a decrease in orders (up from 10% in March), 38% anticipate no change (the same percentage reported as the previous month) and 42% predict an increase in orders (down from 52% in March). However, the current pace of growth in shipments continues to rise, as average daily shipping levels improved in April for the third consecutive month. Sixty-three percent of participants report that shipping

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levels are above levels of three months prior (up from 50% in March), 25% report that shipping levels are the same as three months prior (down from 39% last month), and 12% report a decrease in shipping levels (compared to 11% in March). The percentage of metalforming companies with a portion of their workforce on short time or layoff decreased to 11% in April from 12% in March. The number is at its lowest level since October 2007, when only 8% of companies had workers on short time or layoff, and it is significantly lower than one year ago (42%). “Business for most of the metalforming industry is quite robust, with average orders and shipments for the first two months of 2011 outpacing the same period in 2010 by 16% in orders and 17% in shipments,” says William E. Gaskin, PMA president. “The April business conditions report may reflect concern that there will be a modest softening in the pace of growth as we go deeper into the second quarter. This likely is a result of supply chain uncertainties in the aftermath of the Japanese earthquake, higher fuel prices and higher prices for flat-rolled metals. Business conditions remain very strong for most markets; however, the pace of growth appears to be leveling off as we look toward the summer months.”

• Nearly all (92%) of leading companies are pursuing opportunities to improve accrual management, but only 61% of laggard companies do. • Approximately 60% of leading companies employ proactive means to improve warranty performance through the use of fraud detection methods and early quality warning systems. Less than 20% of laggard companies do.

The significant gaps between leading and lagging companies and the dire need for a robust methodology to improve warranty operations has led to the development of the recently released Warranty Management Capability Maturing Model to help companies assess the capabilities of their warranty organization, develop a continuous improvement roadmap and accelerate business transformation.

FEW MANUFACTURERS CONSISTENTLY BENCHMARK WARRANTY OPERATIONS FRAMINGHAM, MA— According to a recent study published by IDC Manufacturing Insights—Methods and Practices: Warranty Capabilities Maturity Model—while most product companies recognize the criticality of effective warranty management practices, very few companies are addressing the problem effectively. Key findings include: • Most product companies do not consistently benchmark their warranty organizations, with less than 20% of companies even benchmarking internally. • Low product quality and poor warranty coverage and repair can significantly tarnish a brand. However, only a little over half of leading companies and less than 20% of laggards use warranty management proactively to improve their brand image.

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June 2011 | QUALITY

13

FACE OF QUALITY

MANAGE THE HUMAN SIDE OF

QUALITY IMPROVEMENT FOSTER A CULTURE OF CHANGE.

Q

JIM L. SMITH

14

uality professionals and management have a toolbox with a variety of basic quality tools and quality management techniques at their disposal to help manage quality improvement projects and initiatives. Quality professionals are generally proficient in the technical tools; however, we need to understand that the human side of quality is just as important because that is what determines, at the end of the day, real success. Not long ago I found some data results from an on-line survey conducted by The Benchmarking Exchange. Survey respondents were asked to identify their biggest problems when implementing quality improvement projects. The results, in priority order from largest to smallest, include: lack of human resources to implement changes, acceptance of results by department heads, lack of financial resources to implement changes, communicating results and acceptance of results by senior executives. Here are a few steps to overcome these issues: • Establish the need for change. Identify the impact on customer satisfaction, employee involvement and financial returns. However, don’t overlook any potential risks in ignoring the project or moving forward with the change. If we can identify an opportunity that provides not only customer and financial benefits, but reduces the pain and grief for those involved, we have a win-win that everyone can support. You must have full, visible support from senior management. • Assemble the right team. Choose the team that will be responsible to oversee the project recommendations and implementation. Select the best and brightest to lead the effort, carefully choosing representatives from all stakeholder groups. Cross-functional teams with diversity are very important. These teams must be properly resourced and supported by the management team. Team member participation should be recognized as part of their job, with implementation metrics tied to performance reviews. • Define the vision and the strategy. A management sponsor might provide the initial project scope, but every team should confirm the vision and strategy which essentially makes it theirs. The team has to be able to clearly articulate the project’s scope and expected benefits. It is critical to gather all the pertinent data and information through use of a variety of quality tools. Remain focused, but set aggressive goals, which encourage the team to look past incremental improvements and evaluate creative solutions which will bring about exponentially more benefit.

QUALITY | June 2011

•

•

•

•

Move quickly but don’t skip steps. Aim for projects to last 90 to 120 days. Identify project milestones where the project could be terminated and still deliver results. Communicate, communicate, communicate. Second to securing top management commitment is the need to communicate. Develop a communication plan for all stakeholder groups and keep everyone informed. Benefits of the change and resulting benefits need to be told and retold to gain buy-in and continuing support. Stay visible, be open and remain flexible to suggestion that will further the improvement and keep it moving forward. Encourage broad based actions. There are many quality tools and management techniques available for quality improvement projects. Select the right tools for the project. Start with a defined improvement methodology applicable to the scope and nature of the project. A logical, data-driven improvement methodology can ensure recommendations are based on best solution rather than “gut feel” or opinion. Don’t underestimate the time required for implementation. Formulate a detailed implementation plan that includes best and worst-case scenarios. Convince management of the need to resolve any potential problems before implementing the plan. Celebrate success. The team should be properly rewarded and recognized for their team accomplishments. Plan for incremental celebrations when quick wins or a predetermined milestone has been reached. Don’t hide or downplay setbacks if and when they occur. Focus instead on how the setback is being addressed and what changes are being made as a result. Ensure compliance. Control is a huge issue when it comes to change. Many changes stay in place for a while but gradually slip back to the old way. It is important to ensure sufficient controls are in place to prevent a backslide.

People and organizations don’t turn around overnight. Be patient, persistent and flexible. An organization committed to quality improvement will foster a culture of change in which improvement becomes a way of life because it is ingrained in the organization’s DNA. 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

CALIBRATION MISTAKES:

THREAD PLUG GAGES THE MORE COMPLEX THE GAGE, THE MORE ROOM FOR MISTAKES. Editor’s note: This is the fourth installment in a fourpart series on common calibration mistakes.

U

HILL COX

nlike plain plug gages, thread plug gages are more complex—something that will be noticed by even a casual observer. Calibrating them is more complicated as well, as there are more than a couple of simple features on them which have to be verified. The more complex the gage, the more room there is for mistakes to be made during calibration, some of which are noted here.

THE SPECIFICATIONS Most of the standards dealing with screw threads are quite detailed, so a current copy of the relative ASME B1Series document should be reviewed before calibrating gages. Many people rely on their trusty machinist handbook for this type of information, but, as noted elsewhere in this series, their data may be out of Most of the standards dealing date. A common mistake in this area is to assume with screw threads are quite that the handbook infordetailed, so a current copy of mation is all you need to do the job, but this is the relative ASME B1Series rarely the case. These specifications document should be reviewed often include calibration before calibrating gages. process information that is critical to doing the job properly. A mistake frequently made is to apply information on the measurement of threads to other specifications, particularly foreign threads where it does not usually apply. THE EQUIPMENT The most popular device for measuring thread plug gages is a high accuracy bench micrometer-type device. A variety of lower cost devices may be used, but they rarely deliver the performance required with respect to measuring forces and measuring face flatness and parallelism. A mistake that occurs often is selection of the wrong measuring force. A comparator stand with vertically mounted measuring head or indicator may be used for this type of calibration. It often is favored because of the large worktable on which two of the thread wires can be placed when taking pitch diameter measurements. Two mistakes made using this method are to forget that the measuring force will vary with the size of the gage and there is no way it can be adjusted. The indicator

16

QUALITY | June 2011

has to be replaced for one with a different load. The other mistake is failing to have the worktable checked for wear. A critical part of pitch diameter measurement involves the thread measuring wires. Their size and roundness must be within specification in order to do their job, but a common mistake in their calibration is to verify their size while roundness is ignored. Another mistake in respect to thread wires involves the mathematical constant required for their use. Charts and tables in various publications show the theoretically perfect constant for each pitch of wires, and many people make the mistake of using values from those sources. The correct constant is based on a calculation using the calibrated diameter of the wires and this is why, when new, the manufacturer provides this value on the wire container. Laboratories calibrating thread wires often make the mistake of providing the wire diameter in their reports, while ignoring the most important number for the wire user: a value for the constant based on the calibrated wire size. Other mistakes respecting thread wires used in this calibration work is encountered when wires are retained in holders that prevent them from freely locating in the thread. At this point you must be thinking there is little more I can do to beat up on thread wires, but there is. The mistakes involve forgetting that wires in a 60-degree thread form will have their errors incorporated in the size measured on a 3:1 basis because of it. American standards for thread gages require, among other features, that the major diameter of the plug gage be calibrated. Nothing exciting about that—it’s a relatively simple measurement. The mistake that comes into play is not following the standard that requires the measurement to be made using the same measuring force used for the pitch diameter measurement. Another mistake in thread plug calibration is forgetting that thread angle and linear pitch need to be verified if the gage is to be properly qualified. Unfortunately, most companies will not pay for these checks so they remain a mystery that can haunt the users of them later. All the rules I’ve noted elsewhere in this series in respect to gage block buildups as masters also apply to thread plug gage calibration. Hopefully, the mistakes associated with them will be avoided as there are so many possible which are specific to this process on its own. Hill Cox president of Frank J. Cox Sales Ltd. (Brampton, Ontario, Canada). He may be reached at [email protected].

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QUALITY 101 Just like a workman needs the proper tools to complete a project, manufacturers should first spend time to understand from their customers exactly what needs to be measured and to what accuracy. Source: X-Rite Inc.

CONNECTING THE DOTS OF

COLOR MEASUREMENT Instrument manufacturers have come up with sophisticated tools that can help virtually any company to learn and use the language of color for quality control. BY BRIAN D. TEUNIS

E

ven though industries as varied as automotive, aerospace and pharmaceutical manufacturing do not seem to have much in common, they all share the basic need to measure color accurately and reliably so their products adhere to customers’ specifications. Whether the challenge is to measure metallic paint on the side panel of a car or the upholstery of an airliner seat, instrument manufacturers have come up with sophisticated tools that can help virtually any company to learn and use the language of color for quality control. Just like a workman needs the proper tools to complete a project, manufacturers should first spend time to understand from their customers exactly what needs to be measured and to what accuracy. Some common questions include:

18

QUALITY | June 2011

• Which color scale does the customer use? Instruments assign numerical values to the three basic elements of color: hue, chroma and value. There are three common standards that communicate a particular color in the vast universe of possible colors: CIE Xyz, CIE L*a*b* and CIE L*C*h°. • What level of spectral resolution does the customer require? For instance, RGB instruments can only give a relative nonstandard value, colorimeters give one of the above mentioned standard values with moderate accuracy, and a 31-point spectrophotometer gives all the standard color values, plus a full reflectance curve data, at a high level of accuracy. • What system of tolerancing does the customer use and how tight is the tolerance? Some common tolerancing systems include CIELab,

CMC Lab, DE 2000 and HunterLab. Selecting the appropriate system of tolerances is critical because it guards against release of nonspecification product and false rejects. Wide open tolerances may require only a simple RGB instrument, while tight tolerances may require a 31-point spectrophotometer. • How smooth is the surface being measured? Is it smooth like a car panel or relatively rough like the upholstery of a car seat? Some textured surfaces such as cloth are angularly sensitive, meaning that the color measurement is affected strongly by the orientation of a piece. • What type of illumination is the customer using? Many colors undergo a common color phenomenon called metamerism when viewed under different light sources. Two color samples may appear identical when viewed under incandescent illumination but appear very different under daylight. In general terms, customers choose a standard illuminant that best represents the source that will light their products where they are sold. Some standard illuminants include A, C, D50, D65, F2, F7 and F11. Answers to some of these questions may be found by asking how the customer monitors and controls color quality, but often manufacturers need to implement additional color measurement techniques that apply to their particular processes. Many instrument makers provide free advice on the latest methods of measuring color that are tailored to the type of material involved, tolerances and cost of the quality control program. For instance, instrument manufacturers have developed relatively low cost, noncontact in-line devices that measure paints and coatings, plastic injection molded and extruded parts, and even rough surfaces, such a brick, so companies can now afford to continually monitor processes at a particular piece of equipment on the factory floor,

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blue filters that emulate the response of the human eye to light and color. These instruments are used effectively for sorting and quick in-line checks for less exacting jobs. A good visual analogy to compare the scale of resolution of a colorimeter with a spectrophotometer is this: if a colorimeter measures on the scale of inches, a spectrophotometer will measure on the scale of ¹∕16 of an inch. In addition to targeting samples precisely, the new generation of 45/0 degree geometry spectrophotometers have advanced optics and sensors that accurately measure gloss as well as colors. Source: X-Rite Inc.

rather than relying only on occasional sampling in the laboratory. In the past, manufacturers that use lab-confined spectrophotometers would take samples only at the beginning, middle and end of the production runs due the effort and expense involved in the measurement process. New 45/0 degree geometry spectrophotometers can accurately control the quality of color by measuring a wide range of wet and dry samples without touching test surfaces. In addition to targeting samples precisely, the new generation of 45/0 degree geometry spectrophotometers have advanced optics and sensors that accurately measure gloss as well as colors. Using computer software, the instrument can compensate for the difference in appearance between dry and wet samples. Instrument makers have increased the sophistication of spectrophotometers by adding more illuminators and sensors than 45/0 degree geometry instruments so that automotive suppliers and manufacturers can now measure metallic and interference paints that have proven so popular with the vehicle-buying public. But spectrophotometers certainly are not the answer for every color measurement application. In cases where precise color measurement is not required, other families of instruments can represent the most cost-effective solution for the control of color quality. For instance, colorimeters are simpler and less expensive instruments that use red, green and

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There are many applications in everyday manufacturing where a colorimeter is perfectly adequate to the task and a spectrophotometer would be considered overkill. Brian D. Teunis is the market manager for automotive, coatings, plastics, textiles and online at X-Rite Inc. (Grand Rapids, MI). For more information, e-mail [email protected], call (616) 8032389 or visit www.xrite.com.

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June 2011 | QUALITY

19

50 YEARS OF QUALITY

From Luxury to Staple:

CMMs Once considered a luxury for ensuring quality control, coordinate measuring machines (CMMs) are now a staple in both large manufacturing plants and small job shops. This month Quality takes a look back at technology that was developed in the early 1960s.

QUALITY

THROUGH HEAT OR DIRT AND DARK OF NIGHT ..., JANUARY 2002 Coordinate measuring machines (CMMs) have left behind the shackles of the metrology lab o and found a home in a Through Heat or Dirt and Dark of Night... tthe shop, near producF ttion, where they can best be used to conduct b ffast and accurate 3-D measurements of parts m aas they are made. These companies are alone. Manu Manufacturers of a wide not alone variety of products have successfully overcome the difficulties of inspecting parts near production areas. The CMMs can be found on transfer lines, inside manufacturing workcells and as part of elaborate multitechnology turnkey systems. In some cases, the CMMs are off-line but nearby, so that parts can be quickly conveyed or hauled by robot or forklift from machine tools to CMMs for inspection. These sophisticated measurement, test and inspection tools are being used for first article inspection, 100% inspection, and random inspection in pre-process, in process and post process placement—all with the idea of discovering nonconforming parts

CONTROLLING THE MANUFACTURING PROCESS

While a number of concerns must be addressed, many manufacturers have successfully moved coordinate measuring machines from the lab to the factory floor. By Larry Adams Senior Editor

QUALITY TECH TIPS 䡲 Materials are at their exact size at 20 C. 䡲 Temperature affects materials at the microscopic level and can cause parts to expand and contract as they heat and cool. 䡲 Different materials expand at different rates, which is known as the coefficient of thermal expansion (CTE). 䡲 Sensors measure temperature in realtime and software factors in material expansion rates. 䡲 CMM components can be made of temperature-stable materials to provide more uniform CTE.

34

ord Brazil recently integrated five of them onto its shop floor. Up north, in Michigan, GM Powertrain has eight of them that it uses to inspect cylinder blocks, heads and intake manifolds for automobile engines. DVD manufacturers have them, as does an aluminum extruder. And some companies have even designed them into systems for use in unattended, lights-out factory environments. What is them? “Them” are coordinate measuring machines (CMMs) that have left behind the shackles of the metrology lab and found a home in the shop, near

production, where they can best be used to conduct fast and accurate 3-D measurements of parts as they are made. These companies are not alone. Manufacturers of a wide variety of products have successfully overcome the difficulties of inspecting parts near production areas. The CMMs can be found on transfer lines, inside manufacturing workcells and as part of elaborate multitechnology turnkey systems. In some cases, the CMMs are off-line but nearby, so that parts can be quickly conveyed or hauled by robot or forklift from machine tools to CMMs for inspection. These sophisticated measurement, test and inspection tools are being used for first article inspection, 100% inspection, and random inspection in preprocess, in process and post process placement— all with the idea of discovering nonconforming parts before they are shipped to customers or to the next production process. And it is not just large automobile or aerospace companies that are using CMMs in this way. One of the strengths of today’s CMM offerings is that they are affordable for Because of the affordability of today’s CMMs, as well as their factory-friendly construction that allows their use out- smaller companies while side of a metrology lab, smaller company’s such as Wirestill being factory friendly Tech Inc. can take advantage of a CMMs precise measureenough to allow them to ments. Here, Wire-Tech’s Tim Sandecki inspects a part. Photo: L.S. Starrett Co. be used without having to

QUALITY / January 2002 www.qualitymag.com

20

QUALITY | June 2011

before they are shipped to customers or to the next production process. And it is not just large automobile or aerospace companies that are using CMMs in this way. One of the strengths of today’s CMM offerings is that they are affordable for smaller companies while still being factory friendly enough to allow them to be used without having to construct an expensive metrology lab. CMMs were introduced in the early 1960s, but not until the 1990s did CMMs really start to come out from the clean, temperature-stable environment of the laboratory. As part measurements increasingly moved from the lab to the plant floor, CMM suppliers realized that their products must be tough enough to take their places near the machine tools and still provide the kind of accuracy, repeatability and data-analysis capability needed. That means that the CMMs must be shop-hardened with temperatureresistant materials, antivibration systems, protected guideways—such as bearing and scale covers—and scale systems that have low coefficients of thermal expansion (CTE). Variations in temperature are generally considered to be the biggest

problem to be overcome. Temperature affects the base material at the microscopic level and the cumulative effects cause structural changes in both the CMM and the parts being measured. Objects are at their correct size only at 20 C or 68 F and any differences in temperature can affect measurements. The extent of the change depends on the material that the CMM is made of, as well as the material that the part to be measured is made from.

RE-ENGINEERING GIVES CMMS MORE SENSE, MAY 2003 In a perfect world, or in a fully integrated manufacturing environment, metrology systems would be able to measure all necessary parameters in one pass, without error, and feed back results seamlessly to computer-integrated manufacturing networks, in the formats most useful for machine control and process management. One aspect of that utopian vision is the ability of an automated instrument to measure a part, or family of parts, with one setup per part. This vision is what has been driving increased use of coordinate measureRe-engineering Gives ment machines (CMMs) CMMs More Sense I and now, increasingly, toward the use of multisensor CMMs. Demands on metrology technology have never been greater, and the migration of measuring technology toward ward the manufacturing process means a higher level of functionality is required on the measuring side of this equation. QUALITY MEASUREMENT

CMM capabilities can be expanded with additional tools. BY BILL WILDE

n a perfect world, or in a fully integrated manufacturing environment, metrology systems would be able to measure all necessary parameters in one pass, without error, and feed back results seamlessly to computerintegrated manufacturing networks, in the formats most useful for machine control and process management. One aspect of that utopian vision is the ability of an automated instrument to measure a part, or family of parts, with one setup per part. This vision is what has been driving increased use of coordinate measurement machines (CMMs) and now, increasingly, toward the use of multisensor CMMs. Demands on metrology technology have never been greater, and the migration of measuring technology toward the manufacturing process means a higher level of functionality is required on the measuring side of this equation. Multisensor CMMs can be the common

denominator in this equation. The CMM can combine various sensors including a contact stylus and a noncontact laser that are driven through 3-D space to accumulate data points and vision sensors that are able to take measurements of all types. The CMM also has the structural ability to work closer to the actual manufacturing process.

Maximize ROI If CMMs are already in use, making the move to multisensor capability might be less difficult, less costly and offer more functionality than one may think. Paradoxically, the costliest elements in a CMM are its heavy granite base, rigid chassis structure and X-Y-Z drives, not in its high-tech

TECH TIPS

◆ Already owned coordinate measuring machines can be reengineered to include vision, laser and other sensors. ◆ Multi-sensor CMMs can be placed inside a closedloop machining cell for 100% inspection of parts with large dimensions, complex topology or delicate features.

◆ Multisensor capability may provide the flexibility and measurement capability to meet future manufacturing needs.

IN A PERFECT WORLD, OR IN

A FULLY INTEGRATED MANUFACTURING ENVIRONMENT, METROLOGY SYSTEMS

WOULD BE ABLE TO MEAS-

URE ALL NECESSARY PARAMETERS IN ONE PASS, WITH-

OUT ERROR, AND FEED BACK RESULTS SEAMLESSLY.

A traditional coordinate measuring machine uses a touch-probe for collecting measurement data. Photo: Mitutoyo America Corp.

32 QUALITY | May 2003

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Multisensor CMMs can be the common denominator in this equation. The CMM can combine various sensors including a contact stylus and a noncontact laser that are driven through 3-D space to accumulate data points and vision sensors that are able to take measurements of all types. The CMM also has the structural ability to work closer to the actual manufacturing process. C CMMS CREATE FFLEXIBLE FEEDBACK, T MARCH 2005 M The use of coordinate T measuring machines m ((CMMs) in traditional quality control rooms, q isolated from the proi duction floor, often d proves unsuitable for effective and timely feedback on the manufacturing process. The time required to collect parts from the line, take them to the quality control room, thermally stabilize them and run the inspection cycle generally is longer than the manufacturing cycle itself. As a result, the process may produce a large number of nonconforming parts before corrections can be made. The use of a flexible measuring system such as a CMM on the shop floor allows dimensional inspection strategies to evolve from the traditional “adjust by failure” method to the more effective “mastered adjust” approach. This approach focuses on the real-time monitoring of process drifts to prevent the production of defective parts and provide essential information to optimize the process. For more than 25 years, CMMs have complemented traditional dedicated gages or have replaced them. The coordinate measuring operation can be performed quickly when compared with surface plate techniques or fixed gages, meaning that measurement results can be used to cost-effectively refine manufacturing process applications and analyze process trends. To effectively meet the application requirements of dimensional control on the shop floor, CMMs must contain the following: • High inspection throughput. • High level of accuracy to ensure compliance of manufactured parts to design tolerances.

QUALITY MEASUREMENT

CMMs Create Flexible Feedback A dynamic measuring system evolves from simple adjustment to master of real-time monitoring. BY ANNA MARIA IZZI

38 QUALITY | March 2005

he use of coordinate measuring machines (CMMs) in traditional quality control rooms, isolated from the production floor, often proves unsuitable for effective and timely feedback on the manufacturing process. The time required to collect parts from the line, take them to the quality control room, thermally stabilize them and run the inspection cycle generally is longer than the manufacturing cycle itself. As a result, the process may produce a large number of non-conforming parts before corrections can be made. The use of a flexible measuring system such as a CMM on the shop floor allows dimensional inspection strategies to evolve from the traditional “adjust by failure” method to the more effective “mastered adjust” approach. This approach focuses on the real-time monitoring of process drifts to prevent the production of defective parts and provide essential information to optimize the process. For more than 25 years, CMMs have complemented traditional dedicated gages or have replaced them. The coordinate measuring operation can be performed quickly when compared with surface plate techniques or fixed gages, meaning that measurement results can be used to cost-effectively refine manufacturing process applications and analyze process trends.

To effectively meet the application requirements of dimensional control on the shop floor, CMMs must contain the following: ◆ High inspection throughput. ◆ High level of accuracy to ensure compliance of manufactured parts to design tolerances. ◆ Ease of use for operators without specific metrology knowledge. ◆ Ease of load and unload operations and, when needed, integration with the manufacturing flow via hardware and software. ◆ Capability to generate measuring programs off-line without interrupting the normal CMM operation. ◆ Suitable machine protection from the environment and operator protection for personal safety.

Most CMMs are designed to ensure that their components can expand linearly; that is, without induced constraints. These dimensional variations can be calculated and compensated for using linear compensation methods that automatically bring all measurements back to the 20 C reference temperature. Photo: Hexagon Metrology

The speed of temperature variations and the stratifications of temperature in the air create an uneven distribution of temperature in the CMM and cause distortions in the CMM geometry that are more difficult to compensate. CMMs are constructed of different materials and the thermal characteristics of each play a role in this phenomenon. Photo: Hexagon Metrology

Handling environmental effects CMMs, like any other measuring system, are sensitive to environmental factors such as temperature, humidity, suspended dust and oil, and vibrations. For this reason, shop-hardened measuring machines are designed with features that make them more resistant to the environmental influences on shop floor operations. Finding the measuring system that is most suitable for an application requires knowledge of how shopfloor conditions affect measurement perform-

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• Ease of use for operators without specific metrology knowledge. • Ease of load and unload operations and, when needed, integration with the manufacturing flow via hardware and software. • Capability to generate measuring programs off-line without interrupting the normal CMM operation. • Suitable machine protection from the environment and operator protection for personal safety.

MEASURE COMPLETELY AND ACCURATELY, DECEMBER 2006 Inspection is a critical element of any quality program. In addition to the dimensional inspection of workpiece functional elements—typically with tight tolerances— MEASURE COMPLETELY AND ACCURATELY evaluating products I increasingly involves the inspection of free-form surfaces that are not relevant to the function. Examples of such requirements rements include plastic parts such as cell phone cases, housings for electrical plugs or automotive parts. With current technology, geometries with tight tolerances are measured with coordinate measuring machines (CMMs). Complete acquisition of a component requires the use of many rotary and tilt positions. Programming of such measurements requires experience and is time-consuming. Some sensors also require that the component be pretreated, such as being sprayed with white paint to obtain sufficient contrast for optical measurement. What is missing is a measuring device that allows complete, accurate and rapid measurement of the component’s functionally relevant dimensions, regardless of its complexity, without preparation of the component and without extensive programming. Today, a typical first-article inspection report consists of up to 500 or 600 dimensions. In order to inspect the part for function, normally 10% of these measurements are necessary. The rest is used mostly for later reference and, in general, to check for the correct shapes of radii and slopes. Taking into account the state of the projects on which these measurements have to be made, saving time provides potential for improvement. A new system takes advantage of the X-ray computed tomography principle in order to perform measurements during the first out-of-tool (FOT) procedure, as well as for the full firstarticle inspection. The idea behind this approach is to obtain a 3-D point cloud of the entire part with all surfaces and inner geometries, including voids and bubbles. The point cloud can be evaluated by software for all types of applications— |

Q UA L I T Y M E A S U R E M E N T

nspection is a critical element of any quality program. In addition to the dimensional inspection of workpiece functional elements—typically with tight tolerances—evaluating products increasingly involves the inspection of free-form surfaces that are not relevant to the function. Examples of such requirements include plastic parts such as cell phone cases, housings for electrical plugs or automotive parts. With current technology, geometries with tight tolerances are measured with coordinate measuring machines (CMMs). Complete acquisition of a component requires the use of many rotary and tilt positions.

|

Q UA L I T Y S O F T WA R E & A N A LY S I S

|

Many CMM manufacturers provide turnkey measuring systems that optimize the ﬂoor-to-ﬂoor cycle at various automation and integration levels. Source: Hexagon Metrology

Optimize

on the Shop Floor

he primary reason for installing and operating coordinate measuring machines (CMMs) on the shop floor is to keep process quality under control, preventing the production of defective parts. Time is a critical factor. To reduce measurement time to a minimum, only the most critical features should be inspected in a typical process control operation. Nearly all CMMs feature good dynamics and are able to perform positional moves and pick up points very quickly. As a result, measuring programs generally require a short execution time. The measurement cycle itself represents only a small part of the time

Fixtures and automation systems are integral metrology applications B Y A N N A M A R I A I Z Z I required to execute the “ﬂoor-to-ﬂoor cycle”—from collection and loading of parts on the CMM to their removal once inspection is completed. It’s not uncommon to ﬁnd situations in which the loading/unloading operations take considerably longer than the measurement cycle. Some CMM manufacturers provide turnkey measuring systems that optimize the ﬂoor-to-ﬂoor cycle at various automation and integration levels. These measuring systems normally

include the CMM, loading/unloading systems, ﬁxtures and software. They are speciﬁcally designed and built to meet the technical requirements of various applications depending on the type of parts to be measured, part weight, sampling rate, speciﬁc production, and the economic requirements of small, medium and large ﬁrms.

PART FIXTURES FOR DIMENSIONAL CONTROL

Accuracy and reliability of measurement

QUALITY TECH TIPS

Accuracy and reliability of measurement on the shop ﬂoor may be affected by several factors.

40

QUALITY | April 2006

In the case of free-form parts

with low rigidity, such as sheet metal panels, ﬁxtures also have to force the part to take on its nominal geometry.

Separate the handling of measure-

ment and inspection activities from automation activities in order to maintain optimum control of the two activities.

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Multisensor CMMs with computed tomography can measure components without extensive programming. BY JEFF BIBEE

Programming of such measurements requires experience and is timeconsuming. Some sensors also require that the component be pretreated, such as being sprayed with white paint to obtain sufficient contrast for optical measurement. What is missing is a measuring device that allows complete, accurate and rapid measurement of the component’s functionally relevant dimensions, regardless of its complexity, without preparation

of the component and without extensive programming. Today, a typical first-article inspection report consists of up to 500 or 600 dimensions. In order to inspect the part for function, normally 10% of these measurements are necessary. The rest is used mostly for later reference and, in general, to check for the correct shapes of radii and slopes. Taking into account the state of the projects on which these measurements

TECH TIPS

A new system takes advantage of

the X-ray computed tomography principle to perform measurements during the first out-of-tool procedure, as well as for the full firstarticle inspection.

26

OPTIMIZE COORDINATE METROLOGY ON THE SHOP FLOOR, APRIL 2006 The primary reason for installing and operating coordinate measuring machines (CMMs) on the shop f loor is to keep process quality under conCoordinateMetrology trol, preventing T the production of defective parts. Time is a critical factor. To reduce measurement time to o a minimum, minimum only the most critical features should be inspected in a typical process control operation. Nearly all CMMs feature good dynamics and are able to perform positional moves and pick up points very quickly. As a result, measuring programs generally require a short execution time. The measurement cycle itself represents only a small part of the time required to execute the “floor-to-floor cycle”—from collection and loading of parts on the CMM to their removal once inspection is completed. It’s not uncommon to find situations in which the loading/unloading operations take considerably longer than the measurement cycle. Some CMM manufacturers provide turnkey measuring systems that optimize the floor-to-floor cycle at various automation and integration levels. These measuring systems normally include the CMM, loading/unloading systems, fixtures and software. They are specifically designed and built to meet the technical requirements of various applications depending on the type of parts to be measured, part weight, sampling rate, specific production, and the economic requirements of small, medium and large firms.

|

X-ray computed tomography is a

When computer tomography is com-

suitable technology for complete acquisition of components, without part preparation.

bined with precision sensors, rapid, complete workpiece acquisition is possible using tomography and exact measurement of tight tolerances with classical sensors.

QUALITY | December 2006

June 2011 | QUALITY

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space manufacturer. It is true that this approach Portable CMMs GO TO SOURCE OF INSPECTION to quality control and inspection does demand more than what the usual assortment of hand tools and gages can deliver. It places much more emphasis on CMM-based inspections, which could mean a big investment in quality control. However, the new quality practices actually benefit the machine shop, fabricator or tool maker and it costs a lot less then they might expect. By deploying PCMMs to the shop floor, these small businesses are realizing gains without staffing up in the quality control department. These companies are performing thorough and accurate measurements quicker than previously possible. They have adopted a convenient and efficient measurement process that covers everything from incoming inspection through final part inspection. And they have gained greater control over their processes. |

QUALIT Y MEASUREMENT

|

F

PORTABLE CMMS GO TO SOURCE OF INSPECTION, NOVEMBER 2010 For the machine shop that supplies the aerospace industry, portable coordinate measuring machine (PCMM) and model based definition (MBD) are everyday terms that are integral parts of its daily inspection routines. In the effort to drive quality and control processes, aerospace OEMs have altered the inspection methodology and the tools of their entire supply chain. Many of these suppliers are small- or mid-sized machine shops that have invested in inspection hardware, software and processes to satisfy strict quality standards. With the success of these supply chain efforts, portable CMMs and the model based definition inspection technology are expected to spread to all industrial segments. Now, it would appear that these new inspection tools and processes would place a big burden on the machine shop while benefitting only the aero-

or the machine shop that supplies the aerospace industry, portable coordinate measuring machine (PCMM) and model based definition (MBD) are everyday terms that are integral parts of its daily inspection routines. In the effort to drive quality and control processes, aerospace OEMs have altered the inspection methodology and the tools of their entire supply chain. Many of these suppliers are small- or mid-sized machine shops that have invested in inspection hardware, software and processes to satisfy strict quality standards. With the success of these supply chain efforts, portable CMMs and the model based definition inspection technology are expected to spread to all industrial segments. Now, it would appear that these new inspection tools and processes would place a big burden on the machine shop while benefitting only the aerospace manufacturer. It is true that this approach to quality control and inspection does demand more than what the usual assortment of hand tools and gages can deliver. It places much more emphasis on CMM-based inspections, which could mean a big investment in quality control. However, the new quality practices actually benefit the machine shop, fabricator or tool maker and it costs a lot less then they might expect. By deploying PCMMs to the shop floor, these small businesses are realizing gains without staffing up in the quality control department. These com-

Discover how rapid shop ﬂoor inspection makes quick work of quality. B Y RON B R AN C H

This approach is a growing trend outside of the aerospace industry and a strategy that many nonaerospace machining and fabrication shops are using today.

RAPID SHOP FLOOR INSPECTION: THE TOOLS

3-D measurements are taken on the floor at the source for immediate feedback and reporting against the engineering quality specifications. Source: Verisurf

panies are performing thorough and accurate measurements quicker than previously possible. They have adopted a convenient and efficient measurement process that covers everything from incoming inspection through final part inspection. And they have gained greater control over their processes. So, how do these small shops respond to the demands of aerospace manufacturers and realize all of these advantages? They have adopted a rapid shop floor inspection approach: taking 3-D measurements on the floor at the source for immediate feedback and reporting against the engineering quality specifications.

There are three items needed to implement rapid shop floor inspection: hardware, software and engineering data. To conduct inspections on the shop floor, a PCMM is needed. Although there are several options, the common PCMM choice for the small machine shop is typically an articulated arm with a positive contact probe. Temporarily mounted on any rigid surface, these lightweight devices are easily transported anywhere in the shop. Arms have joints that let the machinist extend and rotate the measurement probe into every channel, bore or pocket. With a reach of 2 to 12 feet, the arms do not have physical size limits common with stationary CMMs. These features make them versatile inspection tools. The second component of a rapid shop floor inspection system is the software that receives all of the information from the arm. In the most basic mode, the software will log and report measurements taken with the arm.

TECH TIPS

The common PCMM choice for the small machine shop is typically an articulated arm with a positive contact probe.

20

The PCMM goes to the source of the inspection: all that is needed is a little space and a stable work surface to mount the arm and place the part.

In three simple steps—align, inspect and report—the process is complete.

QUALITY | November 2010

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MEASUREMENT

Multisensor

Metrology Comes of Age

Advances in capability and software make multisensor metrology mainstream. BY BILL FETTER

I

f one was to ask a typical metrology insider what multisensor metrology means, one is likely to get a variety of answers. An unscientific survey at a recent metrology training class proves the point. When asked to explain the topic, the students’ answers included “multiple ways to probe a part,” “using part temperature sensors,” “a machine that has multiple uses” and “different mechanisms inside the probe.” The reality that the term is not intuitively understood points to the fact that this area of metrology deserves some explanation.

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QUALITY | June 2011

Historically, when manufacturers talked about multisensor measurement, this strongly implied a vision-type machine that had one or more additional sensors, such as a touch probe or a laser point probe. Thus, multisensing could be as simple as combining vision and touch probing on a single machine, a capability that has been around for many years. However, in recent years the exploding variety of probing technologies has pushed this description to encompass many different kinds of measurement devices, from traditional coordinate

measuring me machines (CMMs) to vision machines—as long as they contained more than one type of sensor. The reality of multisensor metrology today is best described as hardware and software capability and inspection technique, and not a specific type of metrology platform. In fact, various types of convergence means multisensor technology has made different types of metrology platforms more similar—and more capable—than ever. PLATFORM CONVERGENCE As mentioned above, traditional vision-based measurement platforms have incorporated multiple types of sensors for years. One might call them the original multisensor platforms.

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Multisensor CMMs may include a video sensor on an articulating head. Source: Hexagon Metrology Inc.

Some high-end systems are literally bristling with four or more different types of sensors, from vision to touch and various types of contact and noncontact scanning probes. Recently, with the advent of interchangeable noncontact probes for traditional CMMs, CMMs of all sizes and configurations—from small bridges to the largest gantries sporting touch, analog scanning, laser line and even video probes on the same system—are readily available. In many cases, similar or identical sensors are available on both platforms. Basic sensor types that may appear on either type of platform include: • Vision: A camera-based sensor that measures using the pixels in the camera image. • Touch trigger: A sensor that returns a single measurement point by touching the part. • Analog scanning: A sensor that moves a tip over the surface of the part and returns a dense line of measurement points.

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either because the software could not • Laser point: A noncontact sensor support a multiple sensor setup, or the that returns single points of data via hardware could not, requiring multiple a laser beam. controllers on the same machine. • Laser line: A nonconTECH TIPS It also is generally tact sensor that sweeps the case that each type a laser line over the » Since one can use mulof platform still has its part to return many tiple sensors in a single optimal uses. The vision points of data. inspection routine, the choice of sensor combinaplatform is much bet• White light: A nontions and technique can ter than a CMM for contact sensor that be driven by the applicasmaller parts where the uses a focused white tion requirements. majority of features are light, or light of all two-dimensional. The wavelengths, to return » It is now possible to use the same measurement traditional bridge CMM a highly precise measoftware package for both is better for parts that surement point of a a CMM and a vision system. are on the larger side and fine surface. have three-dimensional » Multisensor metrology today is best described as hardfeatures on multiple faces. It might seem obviware and software capabiliHowever, with the ous that if a system has ty and inspection technique, advent of multiple senmultiple types of senand not a specific type of sors, it is becoming more sors, one could use them metrology platform. common that the capain a single inspection bilities of the two types of program—leveraging platforms are becoming more and more the relative advantages of each type of similar. Since this is the case, smart sensor on a complicated part. However, operators are learning to leverage the this has not always been the case,

June 2011 | QUALITY

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MEASUREMENT benefits of both platforms, and in some instances, even use both platforms in combination on the same parts. CAD INTEGRATION AND PROGRAMMING Since the majority of manufactured parts these days are designed in computer-aided design (CAD) software, most inspection software is CAD-integrated. The greatest advantage to CAD integration is the ease of programming, with the simplicity of point-and-click addition of features to inspect. Some software even allows one to click and drag to add whole groups of features at once—this is a huge time-saver on 2-D parts typical for vision systems. Ironically, the world of 2-D visionbased inspection has been late to incorporate CAD into its software, and as a result, software that has its roots in CMMs have the edge in CAD integration and utility. A multisensor system should have the ability to program all of the sensors from the CAD model in the same

programming environment. Having to switch between different software packages to use different sensors defeats the purpose of multisensor inspection. The capability to program directly from CAD also is essential to be able to develop part programs offline. Not having to program on the machine allows it to stay productive inspecting parts, instead of acting as a programming aid. Offline programming capability allows the simulation of an inspection routine, so one can get an idea of what will happen before the part is ever placed on the machine.

A vision based multisensor platform that includes (from left to right) touch probe, camera and white light sensor. Source: Hexagon Metrology Inc.

and then use the same part program on either a vision platform or a CMM platform. Taking this idea one step further, it is possible to design a part program that is split into two segments, with inspection starting on one type of machine and then moving the part to another—with a common inspection report as the result. One example of a hybrid application might be turbine blades that are inspected on a traditional CMM for speed, accuracy and access to the geometric features, and then moved to a vision-based machine to visually inspect the cooling holes. With cross-platform software, these functions can be programmed offline with the same software from the same CAD model, even though the inspection functions will be performed on different physical platforms with different types of sensors.

CROSS PLATFORM SOFTWARE COMPATIBILITY It is now possible to use the same measurement software package for both a CMM and a vision system. This has advantages beyond the most obvious benefit of a shorter learning curve and more flexibility in the programming staff. With common software it is possible to develop part programs offline from CAD

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QUALITY | June 2011

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THE APPLICATION DRIVES SENSOR COMBINATIONS Since one can use multiple sensors in a single inspection routine, the choice of sensor combinations and technique can be driven by the application requirements. The best example of this is simply matching the data density required with the sensor, so taking low density data—such as touch probe—in areas where simple geometry is sufficient, and using a higher density collector— such as laser scanning—where knowledge of form is necessary, such as on a complex contour. However, sometimes managing the tradeoffs between multiple sensor types and the desired application can take a surprising turn, as in this real-world example: A manufacturer wishes to scan the contours of a surface with high density data (100 thousand points), at a very high accuracy (15 microns), very quickly (10 seconds). One hundred percent inspection was desired. Here’s the tradeoff: • Laser Scanning. Density: Yes; Speed: Yes; Accuracy: No.

• Analog Scanning. Density: Yes; Accuracy: Yes; Speed: No. A multisensor machine can carry both types of sensors, but neither the individual sensors nor combining the two sensors in a single program will accomplish the goal. What is the solution? In this case, the answer was a multisensor CMM with a large physical table, where many parts could be set up on easy load pallets, using a laser sensor as a process capability go/no-go gage to monitor process variability. This allows many parts to be scanned quickly, even though the overall accuracy was not optimal. When feedback from the system indicates variability outside specified limits, the CMM automatically switches to the slower, but more accurate analog scanning probe to perform a high-precision inspection for further analysis. In this case the combination of table size (the ability to set up hundreds of parts at once), multiple sensors and the ability to programmatically vary the inspection process allows a

multiple sensor device to be used in a novel way. Multisensor inspection has moved clearly into the mainstream and is here to stay. Advances in software, sensors and hardware platforms along with the key ingredient of integration have made multisensor systems more capable and useful than ever. The sophisticated metrology user now has more choices and capabilities to improve productivity and efficiency in inspection departments. Q Bill Fetter is the director of marketing for Hexagon Metrology Inc. (North Kingstown, RI). For more information, call (847) 214-5234, e-mail [email protected] or visit www.hexagonmetrology.us.

QUALITY ONLINE Visit www.qualitymag.com for more information on multisensor measurement, such as these features: • “ABCs of Multisensor Measurement” • “Multisensor Measurement— Making Sense of It All” • “Multitasking with Multisensor Measurement”

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TEST & INSPECTION

Advanced Opti

A high-brightness LED array for dark field surface illumination is shown on an optical comparator. Source: Certified Comparator Products

28

QUALITY | June 2011

www.qualitymag.com

ical Technology Opens New Doors

In the 1980s tungsten halogen lamps became commonplace in optical comparators and the new generation of video measuring systems. Tungsten lamps offered the advantage of cooler operation, lower cost and very consistent brightness over their service lifetimes. The performance of tungsten-halogen lamps has improved designed to accommodate a wide range considerably over the years. However, of part sizes and geometries, and typithe typical 12V or 20V halogen lamp cally offer a longer working distance is still limited in its lifetime and between object and lens. This typically brightness, and will generate apprerequires much stronger illuminaciable heat, requiring lamps to be tion. Optical comparators use several remotely located to avoid heating of additional lenses to relay the image to parts being measured. the viewing screen for measurement. In the 1990s, LED light sources Even the best quality optics have some became readily available and quickly degree of transmission loss, and the found their way into many video-based higher the magnification, the greater optical measuring systems. These early this effect can be. LEDs were not very bright, producing For years, optical comparators have less than 100 lumens at normal output, used mercury arc lamps to provide and could be costly and difficult to high intensity light, which could projreplace in the event of a failure. While ect over long distances. While mercury adequate for backlit video measurearc lamps still have their uses today, ments, those early LEDs lacked the they are costly, they creoutput to be practical for ate environmental and BENEFITS surface measurement disposal concerns, and » Today’s optical comparators, of diffuse materials, their intensity degrades digital measuring machines and never achieved the with time. Arc lamps are and multisensor coordinate brightness to illuminate more difficult to automeasuring machine systems the screen of an optical mate too because their are more capable and more comparator. intensity cannot be conaccurate than ever before. Today’s high-brighttrolled directly by vary» Today’s LEDs are reliable, ness LEDs resolve ing current or voltage. compact and can be arranged essentially all of these Optical filters must be into arrays allowing control drawbacks. They are very interposed to lower the in myriad combinations and bright and produce very intensity to suit the situintensities to suit the applicalittle heat load. They are ation. Most significantly, tion at hand. reliable, compact and mercury arc lamps gen» To take advantage of the can be arranged into erate a significant heat new megapixel camera arrays allowing control load which, if transferred technology, the imaging in myriad combinations to the part under inspecoptics must deliver image and intensities to suit the tion, can cause substanresolution that is matched application at hand. tial dimensional changes. to the camera resolution.

Recent advancements in optical technologies are enabling manufacturers to perform dimensional measurements on more kinds of parts, more quickly and more accurately. BY STEPHANIE BLOCH

T

he basic technology for optical measurement of manufactured parts has been commercially available for more than 65 years. As optical technologies have advanced, so have the capabilities of optical inspection and measurement systems. Today’s optical comparators, digital measuring machines and multisensor coordinate measuring machine (CMM) systems are more capable and more accurate than ever before. Recent advancements in optical technologies are enabling manufacturers to perform dimensional measurements on more kinds of parts, more quickly and more accurately.

LIGHTING THE WAY The fundamental principle of optical measurement is that light is manipulated to form a precisely magnified image of an object, and the image is measured, rather than the object itself. So first and foremost, there must be enough light to create an accurate image. In a simple microscope, providing sufficient illumination to image an object is relatively easy: the distance between the object and objective lens is very short, the optics are small and of good quality, and the image sensor— the human eye—is very sensitive, even in low light situations. In practical industrial applications, providing sufficient illumination is not as easy. Measurement systems must be

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June 2011 | QUALITY

29

TEST & INSPECTION

CAD model and tolerance bands are projected on an optical comparator screen. Source: Certified Comparator Products

Small LED arrays can produce more than 1,600 lumens of intensity in broad spectrum or monochromatic wavelengths. They can be multicolored, enabling use of color discrimination to improve image processing capabilities. The technology of LEDs has advanced so that high brightness LEDs can now be used as the exclusive light source in optical comparators, vastly simplifying the operation, maintenance and safety of comparators, even at high magnifications. SEEING THE BIG PICTURE Video camera technology also has made big advances in the past few years. The cameras used in early video measuring systems were far less sensitive than those available today, and whole classes of materials—such as black plastic—were difficult to illuminate brightly enough to make automatic measurements. Elaborate processing

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QUALITY | June 2011

schemes were needed, such as storing and summing-up successive frames of video to “boost” image brightness. Today’s imagers not only work in lower light, they also have substantially more pixels packed into the same size imaging array. Advanced fabrication technology enables very high resolution silicon-based cameras to be produced quickly and cheaply. However, metrology cameras have lagged behind consumer cameras in terms of pixel resolution for good reason: metrology cameras have far more stringent requirements than ordinary imagers. Cameras well-suited for measurement must have very symmetrical pixels, minimal spatial variation and be thermally stable. They must offer automatic gain control, and have high-speed interfaces, such as FireWire or GigE, to enable fast transfer of their massive dataloads to

the image processing system. Most important, cameras for precision measurement must have proven stability over time. Thus, evaluation and selection of metrology cameras takes considerable time and care. Until recently, VGA format cameras (640 x 480 pixels) were the industry standard for metrology, but increasingly, megapixel format cameras—1.0, 2.0, 5.0 or higher million pixels—are becoming reliable and reasonably priced alternatives. The improvement in pixel resolution offers a number of practical benefits for measurement. First, with improved pixel resolution comes the potential for greater measurement resolution. Because most image processing algorithms are capable of 10:1 or better sub-pixel resolution, working with a smaller pixel enables even finer resolution. A more subtle benefit is that virtually all image processing algorithms rely on having some minimum number of pixels in transition to accurately determine an edge location. With smaller pixels, the minimum pixel requirement can be met with a more sharply focused image, making these cameras better suited to use with high-magnification microscope optics for very small feature size measurements. At the other end of the scale, a higherresolution camera often allows use of a lower magnification for larger feature size measurements, thus providing a larger viewing area with equal or better resolution than would be afforded by a standard format camera. SHARPEN THE FOCUS Very high resolution cameras place other demands on an optical system designed for dimensional measurements. In most cases, it is not sufficient to simply put a multimegapixel camera on a standard optical system. Much like point-andshoot digital cameras, the quality of the optics is equally or even more important than number of pixels when it comes to image quality. To take advantage of the new megapixel camera technology, the imaging optics must deliver image resolution that is matched to the camera resolution. Higher optical resolution is achieved by increasing the numerical aperture

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A single image snapshot and multiple images captured in continuous fashion and stitched create a single large image for high speed measurement. Source: View Micro-Metrology

(N.A.) of the optical system, and this is more easily done by increasing the magnification. However, increasing magnification is not always practical in industrial applications. The higher the magnification, the smaller the viewing area, so more stage motion is required to measure large features. Such motion not only takes time, it also adds more variability in the measurement accuracy. Thus, the challenge to designers of optical systems for precision measurement is to provide high resolution with a reasonably large field of view and practical working clearance.

HIGH-SPEED IMAGING The combination of very high intensity lighting, high-resolution optics and cameras presents another opportunity for optical metrology—the ability to measure objects in motion. While speed has always been a hallmark of optical measurement, throughput is still limited by the need to move the part stage so that the desired feature is in view, then stop and settle before a video snapshot is acquired. While this technique is adequate for many classes of parts, those with a very high feature density, such as wire-bonded chips or

printed circuits have always presented a dilemma—either compromise the number of sites measured, or take the time to measure all of them. Faced with this choice, all too often manufacturers are forced to accept the compromise of a smaller sampling rate to be able to acquire data within a reasonable time. The availability of cool, high intensity lighting and high speed, high resolution cameras changes this picture. Combining these technologies offers the ability to continuously acquire images without actually stopping the part stage. This technique, known as

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TEST & INSPECTION continuous image capture, can offer as much as 100 times faster measurement speed compared to traditional moveand-measure techniques. However, implementing this technique is not simple. Because the part is never still, the illumination must strobe with short bursts of very high intensity to prevent “smearing” of the image as frames overlap. In theory, the light pulse must be infinitely bright for an infinitely short period of time. High brightness LEDs make this possible, but the LEDs themselves must be capable of being driven very hard, and the drive electronics must have fast switching speed and high power output. Only recently has LED technology reached the level that reliable, low-cost devices are available that meet these requirements. In addition to the LEDs, the video, lighting and stage servo motion controls must be synchronized such that each frame can be processed without smearing and with sufficient overlap so that there is no gap when the

An increased viewing area afforded by ²∕3-inch megapixel camera array compared to a standard VGA format camera. Source: View Micro-Metrology

strobed images are stitched together. For maximum efficiency, the image processing software must be capable of stitching the strobed images into one large image, and processing the indicated measurement locations in parallel with data acquisition. DIRECT FROM CAD Another optical technology that has advanced the state of the art is image

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projection, based on the digital light processing (DLP) technology invented by Texas Instruments. Traditionally, optical comparators use custom-made chart gages to overlay dimensions and tolerance zones on the projected image of a part. These go/no-go charts enable an operator to quickly determine a part’s tolerance condition and clearly see where there is too much or too little material. While highly accurate, a special chart is needed for each and every part inspected, at each inspection magnification. For parts larger than the viewing area, multiple charts are required. Now imagine if it were possible to directly project an overlay chart from the computer-aided design (CAD) model, which could move as the part stage is moved. Indeed, today’s most advanced optical comparators can do just that, using DLP technology. Projecting an accurate, undistorted CAD image is not simple, but with attention to the right details in the optics, and with software correction for certain effects, very accurate overlays can be projected directly from CAD. BENCHTOP CONVENIENCE The availability of these new optical technologies is enabling a new class of measuring machine known as the digital measuring machine (DMM). These compact, benchtop measuring systems combine high-resolution cameras and high brightness LEDs with unique optical systems offering a very large viewing area, to enable virtually instantaneous measurement of complex parts. Because DMMs typically do not have moving stages, very little effort is needed to set up automatic measurement routines. The key technology in the DMM is the telecentric, long working distance optical system. With this type of optical arrangement, all of the measurements on a part more than 3-inches wide and 2-inches thick can be performed in one video snapshot without the need to fixture the part. What makes this large viewing area practical is telecentric design with very low distortion across the entire optical field. Unlike conventional vision systems which require all feature measurements to take

QUALITY | June 2011

www.qualitymag.com 12/10/07 1:35:54 PM

BALL BAR - DUMBELL place at or very near the center of the field of view, the DMM optics allow a feature located anywhere in the viewing area to be measured with the same resolution. Digital zoom provides multiple levels of magnification, enabling processing of the entire area image with high resolution and small effective pixel size, all with no moving parts. Also key to the capability of these DMMs is their measuring software. The biggest hurdle to overcome in making advanced optical technologies universally accessible is to simplify the setup and operation of automatic measurement routines. Advances in image processing and metrology software now enable measurements to be made without explicit programming steps. For example, the capability for feature extraction—the ability to automatically identify and measure primitives such as lines, arcs and circles from within a video snapshot—have existed for many years. A recent advancement

over simple feature extraction is the technique known as auto-correlation, which “remembers” groups of primitives and their relationships within a scene, enabling recognition of parts, regardless of orientation. While many of the basic technologies outlined here have existed in various forms for some years, recent times have seen considerable refinement of the raw technology into practical, user-oriented measuring systems that are easy to use and cost effective. Manufacturers today no longer have to compromise accuracy for speed, or resolution for flexibility when selecting an optical measuring system. All these technologies are available in one package, ready to transform the art of measurement into the science of process control. Q Stephanie Bloch is senior optical engineer at Quality Vision International (Rochester, NY). For more information, visit www.qvii.com.

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SOFTWARE & ANALYSIS

Advances in

Mobile Data Collection Extend Quality’s Reach

Today’s portable devices allow quality analysis technologies to extend beyond the plant floor for complete traceability and enhanced collaboration. BY DOUGLAS C. FAIR

T

communications have become commonoday’s consumer electronics are place for consumers. extraordinary. From advanced deskSo why not leverage this same techtop computers and handheld devices to nology in manufacturing? Communicacellular telephones, advanced, simpletion, collaboration and visibility are key to-use electronics are found everywhere. factors in managing quality from site What makes them truly exceptional is to site and from supplier to manufactheir ability to link to cellular networks turer. Using mobile devices to capture and the Internet, resulting in a global and share data where it was previously interconnectedness that, just a couple of unable to be collected has the potential decades ago, was the stuff to dramatically improve of science fiction fantasy. BENEFITS product quality. Immediate communi» The use of mobile data colcation with people in diflection hardware to enter ferent countries is the rule CURRENT STATE critical quality and traceabilrather than the exception. Many manufacturers ity information and provide “Free” international phone operate in a technological data accessibility worldwide calls can be made without stone age when it comes is underutilized today. the use of traditional teleto data collection and » Communication, collaboracommunications technolstorage. New technolotion and visibility are key ogies. Cell phones make gies are rarely used for factors in managing quality calls without consuming logging quality or inspecfrom site to site and from cellular minutes. These tion data. To prove it, just supplier to manufacturer. easily accessible and inexlook around a manufac» Using mobile devices to pensive technologies allow turing facility—few comcapture and share data us to be on-line no matter puters are found on the where it was previously where someone is and shop floor. Instead, the unable to be collected has at little cost. As a result, use of paper and pencil is the potential to dramatically improve product quality. global, instantaneous most prevalent.

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Product feature checks, checks safety checks, setup checks and a variety of other critical-to-quality data are still written on paper. Sometimes the data values are transcribed onto spreadsheets. Even then, different formats, errors in transcription and the cost of double-entering data can make the spreadsheets difficult to work with. They languish on individual computers like the electronic versions of paper that they are. Paper use is so widespread in some companies that on-site “librarians” are employed to manage the large amount of records. THE RESULT Paper-based systems make reporting extremely challenging. This is true even when the data has been typed into spreadsheets. A corporate quality director once relayed that it took a team of five people six entire days to track down all the quality data for one of its products. Why? Because the data the team needed was scattered across several paper-based systems. To complicate matters, most information technologies are focused on the plant itself. While on-site software products may be leveraged in lieu of paper, there exists minimal interest in communicating quality data outside of a plant’s four walls. Whether between supplier and manufacturer or from

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Today’s quality infrastructures allow for data collection and analysis using an assortment of tablets and other mobile devices. Source: InfinityQS

one corporate-owned plant to another, there is a sense of “what’s mine is mine and what’s yours is yours.” As a result, plants and systems are often disconnected with little or no ability to communicate data outside of the four walls. THE FUTURE TODAY There are some manufacturing companies who have moved away from paper-based systems in exchange for electronic and even Web-based solutions. In fact, most companies already possess the infrastructure necessary to support mobile data collection, including access to: 1. A wired or wireless network 2. The Internet 3. A cellular network 4. Portable handheld electronic devices such as tablet computers and cellular telephones 5. Software-as-a-Service (SaaS) If unfamiliar with Software-as-a-Service (SaaS), consider how bank account balances can be checked online. Basically, users pull up a Web site and log in. That’s all. No need to install software

on your computer. In fact, one doesn’t need a computer at all. You can check your balance using a tablet computer or smart phone from anywhere. Instantaneous access is available no matter the time of the day or the country in which you are standing. Best of all, when transactions occur, they are automatically posted. So when you check your balance, you are privy to the most upto-date data available, all in real-time. EXAMPLE Now imagine that this technology has replaced paper on the manufacturing shop floor. An operator uses a gage connected to a traditional computer to periodically measure his or her products and enter results. A roving inspector with a tablet computer slung over her shoulder walks from one production line to the next logging defect codes. A process engineer performs confirmatory checks with his cellular phone. Regardless of the hardware used, data is passed to a single, shared, centralized database. Database location is unimportant. It could be somewhere in cyberspace, such as a bank’s database. The critical

component is that the database is secured and users have access to the data. At the same time data is being entered, the plant’s quality manager is visiting a supplier. His plane has just landed in China. He takes out a handheld device, logs onto a wireless network and clicks a link. The result is a summary report of his home plant’s quality data for the past 24 hours. Because the quality checks are entered in real-time from his plant, the most recent data is always available. No waiting for a clerk to gather up paper on the shop floor. No waiting for an administrative assistant to interpret hand-written numbers and type them into a spreadsheet. Imagine also that his Shanghai supplier enters their quality data into the same database. As the quality manager gets into his taxi he logs onto the local cellular network. Then, he clicks on a different link on his cell phone. A report summarizes the Shanghai plant’s quality information for the past week. Since everything is online, he also receives e-mails from China when defect levels increase or when an alarm is triggered.

Companies are using mobile devices to collect and analyze data from an unlimited number of sites and suppliers. Source: InfinityQS

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SOFTWARE & ANALYSIS

Regardless of where production takes place, portable data collection brings the quality system directly to the product. Source: InfinityQS

MOBILE DATA COLLECTION BENEFITS Nothing is actually new or futuristic about the aforementioned scenario. Instead, all of these technologies are readily available, and even inexpensive. Some of the most cutting-edge manufacturers are already employing these technologies today to save time, improve communication and control quality on a global level. These technologies make data collection, communication and global plant reporting easy. Most importantly, leveraging these technologies for quality systems should help mitigate or reduce the possibility of low quality or unsafe products getting into consumers’ hands, while minimizing costs across the supply chain. Here are some other benefits of mobile data collection: • Collaboration. Problem-solving activities are driven by data. Without it, corrective actions are virtually impossible. Imagine that when an issue occurs, experts have instantaneous access to the data surrounding the event. When an alert is triggered

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by off-quality product from a supplier in China, a quality engineer in Chicago receives an e-mail describing the event. Together, the responsible parties in both countries discuss the issue. These discussions lead to process control actions necessary to ensure off-quality product does not enter the supply chain. By doing so, global costs can be reduced while quality levels can be increased by those sharing a vested interest in the outcome. • Traceability. Typically, organizations like to associate traceability fields, such as the shift, lot code or batch, to their quality data. That way, data can be “sliced and diced” based on what is most important. Now, assume that each vendor and supplier associates a common traceability field—such as a lot code—to each manufacturing step at each plant. From raw materials and subcomponents to final product assembly, data is passed to a shared database. If so, then “wombto-tomb” traceability would be a reality. No more paper. No more

mailing certificates of analysis. Users could just log onto the database, type in a lot code and get the information they need. • Reporting. If traceability information is leveraged from one production step (and plant) to the next, the result is a linkage from raw materials to finished goods. If there happens to be a problem with a finished lot, all of the components, subcomponents and raw materials can be traced. This traceability dramatically improves the ability to track down problem causes and minimize recall costs. Also, raw materials can be traced to final finished goods. Manufacturers can trace global raw material consumption to the last plant where finished goods are packaged through a genealogical “tree.” In effect, mobile data collection and its related technologies could optimize supply chain efficiencies by dramatically improving information exchange while allowing an unheardof level of flexibility in data collection and reporting. By doing so, manufacturers could not only reduce overall costs of data collection and reporting, but they could further reduce global quality costs, protect final consumers from off-quality products and greatly expand data accessibility. While consumers enjoy a connectedness on par with something out of a science fiction novel from the 1960s or 1970s, manufacturing organizations, for the most part, have not been early adopters. And yet, the technology is available if they choose to use it. The use of mobile data collection hardware to enter critical quality and traceability information and provide data accessibility worldwide is underutilized today. It is as easy as leveraging existing IT infrastructures with commonly accessible and cost-effective mobile consumer technologies. By doing so, organizations can further remove costs from the overall supply chain, minimize the possibility of expensive recalls, prevent problems and improve product quality on a global scale. Q Douglas C. Fair is VP of statistical applications at InfinityQS (Chantilly, VA). For more information, e-mail [email protected], call (703) 961-0200 or visit www.infinityqs.com.

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MANAGEMENT

Strategic Business Improvement in the

New Economy The future is recognition and cultural acceptance of accelerated, technology-driven sustainable strategic improvement with unlimited possibilities, and unlimited competitive rewards for success. BY TERENCE T. BURTON

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ost organizations are emerging from the largest recession and slow recovery since the Great Depression. Unfortunately, the reactionary and inconsistent leadership responses to the meltdown have become the new cultural norm in organizations, taking culture backward and destroying their ability to improve anything. Organizations have placed a freeze on improvement when they need it the most. The majority of organizations currently find themselves in a derailed state with their Lean Six Sigma initiatives, and a solid foundation of strategic and sustainable improvement in general.

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THE EVOLUTION OF MELTDOWN MANIA Through the economic meltdown and recovery, there is no doubt that executives have moved formal improvement initiatives such as Lean Six Sigma further down on their priority list. The recent meltdown and stalled recovery continues to spawn many interesting attitudes about improvement reflected in a few actual comments: • There’s no money in the budget for improvement until 2011-2012. • The time is not quite right for improvement. • Improvement is not in my goals and objectives.

• We eliminated our Six SSi Sigma i gm g a program. It did not work for us, we’re different. • We don’t have the time and resources to improve and do our regular jobs. Today, many organizations may not openly admit it, but they have traded in their true commitment to Lean Six Sigma for a gamut of leadership behaviors that are driving culture backward, all in the interest of short-term results. True strategic improvement is definitely off-the-tracks and behind the financial statement scene, the hidden waste continues to pile up on a global scale. You can be sure that the Piper will demand payment plus severe consequences from organizations who continue in this short-sighted modus operandi. There are two facts about waste in organizations: First, waste is dynamic and everywhere, and the growth rate of waste is proportional

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to executive behaviors and strategic choices about improvement. As the world accelerates, so too must the process of improvement. Second, when waste is left unattended, it spreads like a cancer through organizations. When people have the perception that improvement is no longer a priority and follow suit with reactionary behaviors, the organization fails to recognize the obvious—the only way to get better is to improve the current state. Historically there has been this disturbing birth-death cycle of improvement. When things are good, improvement is the first casualty because it is perceived to be no longer necessary. When things are bad, improvement is the first casualty because people do not have the time and resources to improve and do their regular firefighting jobs. Between these two extremes, improvement has been supported by temporary and wavering commitments, token agreements, fad programs, massive training and symbolic motions of improvement. Improvement

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always fades away as an expected core value and enabler of business and cultural success because organizations are missing the core competency of keeping the word continuous in continuous improvement.

» Many organizations have traded in their true commitment to Lean Six Sigma for a gamut of leadership behaviors that are driving culture backward, all in the interest of short-term results.

THE NEXT GENERATION OF IMPROVEMENT The next generation of improvement is Improvement Excellence: The mastery of developing and implementing successful strategic and continuous business improvement initiatives, transforming culture and enabling organizations to “improve how they improve.” This sounds so simple and logical—take the

» Executives must now make the right new choices about improving how they improve in this nonstop global economy, or they will fall behind at an increasingly rapid rate.

TECH TIPS

» Improvement excellence is the mastery of developing and implementing successful strategic and continuous business improvement initiatives, transforming culture and enabling organizations to “improve how they improve.”

» Technology is the integrated process architecture and critical enabler of transactional enterprise improvement in this rapidly developing global environment.

improvement methodologies already available to us, adapt the process of improvement to the changing economy and evolving global requirements, and build a permanent and sustainable capability to continuously improve how we improve and stay the course this time. However, Improvement Excellence is a legitimate core competency that is missing in most organizations. The Improvement Excellence framework recognizes this need for dynamic and adaptive strategic improvement, continuously evolving to specific market, customer and enterprise needs. Strategic improvement is deeply engrained in culture via sustainable infrastruc-

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MANAGEMENT Source: Bombardier

THE 10 ACCELERATORS OF LEAN SIX SIGMA RESULTS STRATEGIC LEADERSHIP AND VISION 1. Reinvent and Reset Leadership, Improvement Strategy and Vision

STRATEGIC LEADERSHIP AND VISION

DEPLOYMENT PLANNING

DEPLOYMENT PLANNING 2. Develop a Robust Deployment Plan 3. Provide Customized Education and Development 4. Communicate, Communicate, Communicate 5. Launch with the Best in Mind EXECUTION 6. Provide Strong Extensive Mentoring Support 7. DMAIC the Deployment Process Regularly 8. Accelerate Individual Project Paths 9. Complete the C in DMAIC 10. Practice Concurrent Continuous Deployment

EXECUTION

Improvement Excellence Framework

ture and incorporates the characteristics that follow.

Source: The Center for Excellence in Operations Inc. (CEO)

of DMAIC (define, measure, analyze, improve and control) or specific tools, and the scope is limited to the three to five critical issues that keep everyone up at night vs. mass, non value-added improvement activity for activity’s sake. Scalable Lean Six Sigma is a strategically targeted and scalable approach, achieving rapid deployment and of course, rapid quantifiable and sustainable results.

PERMANENT AND SUSTAINABLE INFRASTRUCTURE MATTERS Sustainable continuous improvement is built into organizational culture via a very structured and formal infrastructure. The elements of this infrastructure include strategic leadership and vision, deployment planning and execution. This formal infrastructure keeps the notion of improving how we improve in the forefront of the typical ongoing changes in executives and leadership directions, conflicting priorities, political motivations, a focus on short-term performance and other potential distractions to strategic improvement. Infrastructure links and closes the loop between individual improvement success and global business success.

TEN PROVEN ACCELERATORS OF SUCCESS Today improvement is all about rapid deployment and rapid results. This is achieved through the 10 accelerators embedded within the Improvement Excellence infrastructure of strategic leadership and vision, deployment planning and execution. These specific and deliberate activities accelerate the process of improvement and include the following:

AN ADAPTIVE AND NIMBLE PROCESS OF IMPROVEMENT The process of improvement is customer-centric, adaptive and more nimble. Improvement Excellence uses a methodology called Scalable Lean Six Sigma, which is a simplified but high impact alternative to the traditional top down, mandated, overhead intensive, single point, train-the masses approach to improvement. The focus of Scalable Lean Six Sigma is on the efficient process of improvement rather than the naive application

1. Reinvent and reset leadership, improvement strategy and vision 2. Develop a robust deployment plan 3. Provide customized education and development 4. Communicate, communicate, communicate 5. Launch with the best in mind 6. Provide strong extensive mentoring support 7. DMAIC the deployment process regularly 8. Accelerate individual project paths 9. Complete the C in DMAIC

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10. Practice concurrent continuous deployment Collectively, the 10 accelerators of Lean Six Sigma results address the true improvement challenges of the new economy. These accelerators are not limited to Lean Six Sigma; many of the accelerator concepts are directly transportable to many other strategic initiatives such as improving outsourcing processes, mergers and acquisitions, reducing costs of Sorbanes-Oxley compliance, product and portfolio rationalization, building a new facility in China, IT strategy and deployment, or rationalizing global supply chains. THE CONVERGENCE OF ENABLING TECHNOLOGY AND STRATEGIC IMPROVEMENT In the new economy, technology is enabling the warp speed transformation of organizations into global, multilevel networks of transactional enterprises. Unlike manufacturing improvement, transactional improvement is transparent and comprised of key business processes, information flows, knowledge and decisions. Further, there are literally hundreds of people managing thousands of dynamic process touch points, a continuous churn in requirements, specific country requirements, time constraints, communications issues and exponentially greater opportunities for waste, variation and bad decisions.

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Accordingly, technology and business process knowledge have become much more important to the success of the next levels of Lean Six Sigma and strategic improvement in general. No longer is the notion of enabling technology and process improvement mutually exclusive or sequential. Technology is the integrated process architecture and critical enabler of transactional enterprise improvement in this rapidly developing global environment. TIME TO MOVE FROM RECOVERY TO DISCOVERY The impulsive leadership actions to the 2008 meltdown are a natural response to disaster, leaving executives and organizations vulnerable to bad choices. There are no shortcuts to successful strategic improvement, and the expediency of impulsive actions only trumps the propriety of logical improvement thinking, resulting in a dazzling display of illusive success. What is done is done, and that is yesterday’s rain. Today, executives must now make the right new choices about improving how

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Today, executives must now make the right new choices about improving how they improve in this nonstop global economy, or they will fall behind at an increasingly rapid rate. they improve in this nonstop global economy, or they will fall behind at an increasingly rapid rate. The silver lining to all the negativity of the past 18 months is that there are more global opportunities for improvement and competitive success than any other time in history. It is time for organizations to get serious with strategic improvement, use what is already available to us effectively, inject creativity, velocity and a renewed focus into the process of improvement, and improve how they improve. Some organizations get it and are well into their new journey of improving how they improve, integrating technology with a well structured, targeted and scalable improvement process. Many of these

organizations also stayed the course of improvement through the meltdown and recovery, and are now in a strong offensive and proactive position of strategic improvement. This is the future—the recognition and cultural acceptance of accelerated, technology-driven sustainable strategic improvement with unlimited possibilities, and unlimited competitive rewards for success. Q Terence T. Burton is president of The Center for Excellence in Operations Inc. (CEO, Bedford, NH). His latest book, “Accelerating Lean Six Sigma Results: How to Achieve Improvement Excellence in the New Economy,” on which this article was based, was released in January 2011. For more information, e-mail [email protected] or visit www.ceobreakthrough.com.

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CASE STUDY The Falcon 9 lifts off from SLC-40 for the first test flight of Dragon spacecraft. Source: SpaceX

LOFTY GOALS DEMAND

PRECISE POSITIONING Verisurf metrology software helps Space Exploration Technologies maintain precision in the shop and on the launch pad for its vehicle development and launch services.

W

payload to the International Space ith the retrieval of Dragon Station, which the company plans to from the Pacific Ocean, Space initiate by the end of 2011. For these Exploration Technologies (SpaceX, future missions, SpaceX will again turn Hawthorne, CA) became the first comto its portable coordinate measurmercial company to launch ing machine (PCMM) and recover a spacecraft BENEFITS systems to maintain the from low-Earth orbit. » Model based definitions precision it achieved Placed into space atop the (MBD) with profile tolerwhen first launching company’s Falcon 9 launch ances eliminate the time to and returning Dragon vehicle, Dragon completed document an engineering from orbit. two orbits with speeds drawing, reduce the time SpaceX is a different topping 17,000 miles per to create inspection plans kind of company, in hour. After its three-hour, and reports and accelerate part due to its founder 50,000-mile flight, Dragon identification and resolution of manufacturing issues. and CEO, Elon Musk, splashed down just one who was co-founder mile from the center of its » The Verisurf solution of PayPal and is the targeted landing zone. measures parts and toolCEO of Tesla Motors. This is the first of three ing during fabrication and manufacturing. In a post-flight press test flights under NASA’s conference, Musk Commercial Orbital » The Verisurf system shows says, “The reason I’m Transportation Services the computer-aided design doing SpaceX is that (COTS) program. Follow(CAD) model and the meaI just happen to have ing two more test flights, surement results reflected against the 3-D model. a very strong passion Dragon will be delivering

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for space, and I want us to become [a] true spacefaring civilization and even a multiplanetary civilization.” To make his goal a reality, SpaceX intends to change 40-year-old paradigms with a family of launch vehicles and spacecraft that increase reliability and performance while ultimately reducing costs by a factor of 10. The underlying philosophy is a focus on simplicity to both increase reliability and lower cost for vehicle development and launch services. According to Larry Mosse, SpaceX’s tooling operations manager, the company counts on its PCMMs to deliver this reliability and cost reduction. And it counts on Verisurf’s (Anaheim, CA) metrology software to drive all these devices in a powerful yet simple way. He says, “Verisurf metrology software is doing its part in maintaining precision in the shop and on the launch pad. We use it for everything from tooling fabrication to pre-launch preparation.” HITTING PRECISE MARKS Falcon 9 lifted off from Cape Canaveral AFS launch pad SLC-40 at 10:43 a.m. EST on December 8, 2010. At 10:52 a.m., Dragon entered low-Earth orbit. At 2 p.m., Dragon splashed down. At every point in this mission, the launch vehicle and spacecraft hit their marks precisely. According to the company, Falcon 9 delivered Dragon to orbit with “near bull’s-eye insertion,” and Dragon then splashed down in the center of its targeted landing zone. The accuracy of the f light path required careful alignment of Falcon 9’s sections and precise launch vector positioning. So, the SpaceX crew used its PCMM metrology systems, which included laser trackers and Verisurf software. Falcon 9 is 180 feet tall and has a 12-foot diameter. Nine of SpaceX’s Merlin engines power the first stage; the second stage uses one. Final assembly is completed at the launch site. To position and align Falcon 9’s components, SpaceX used laser trackers and Verisurf ’s Build application, which is a virtual gage. The trackers fed measurement data

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directly to Verisurf, which reported, in real time, the accuracy of each section relative to the computer-aided design (CAD) model used in design and manufacturing. After assembly, the SpaceX crew raised Falcon 9 into its vertical launch position. To follow its intended flight path, launch specifications allowed the vector of the vehicle to deviate by only 0.02 degree over the 180-foot length. Mosse says that the crew again turned to the PCMMs and Verisurf Software to confirm a “ready-tolaunch” status. “The specs allowed the nose to be off of vertical by six inches,” he notes. “Verisurf reported that we had only a one-hundredths inch deviation east to west and threehundredths from north to south. And from the ground up, all sections were at their nominal positions.” UNDER CONTROL Mosse notes that this alignment accuracy was possible because of the controls used in manufacturing and assembly operations at the company’s Hawthorne, CA, facility. He cites one example: “We have a set of five fixtures that are used to position rocket components and drill a pattern of 144 holes. These holes dictate the alignment of Falcon 9’s sections.” As he did in preflight preparation, Mosse used Verisurf to place the fixtures before committing to the drilling operations. “With Verisurf, we are looking directly at the CAD model and the measurement results,” Mosse states. “We see the measurements reflected against the 3-D model. This makes the process faster and reduces mistakes.” He notes that before Verisurf his team had to interpret page-after-page of 2-D drawing dimensions. “We had to rely on people’s ability to visualize 3-D measurements from 2-D drawings, which results in interpretation problems,” he says. Before assembly, Mosse used his Verisurf solution to measure parts and tooling during fabrication and manufacturing. For example, SpaceX will drive both laser trackers and articulating arms with Verisurf when measuring composite tooling or weld fixtures. “We inspect these items to the CAD data. In many cases, we will inspect to profile tolerances only,”

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Pictured above is an artist rendering of Dragon, with solar panels extending, in orbit. Source: SpaceX

Mosse says. “We aren’t drawing-free, yet, but like the rest of the aerospace industry, we are striving to implement

model based definition to achieve its many benefits.” For SpaceX the most important benefit is time. Model based definitions (MBD) with profile tolerances eliminate the time to document an engineering drawing; reduce the time to create inspection plans and reports, and accelerate identification and resolution of manufacturing issues. With an aggressive schedule and a 25-launch manifest over the next four years, including 12 space station deliveries, every moment counts. SpaceX’s philosophy for its launch into space is simplicity that yields reliability and savings. To achieve this, it counts on Verisurf. Mosse says, “With Verisurf, we have very quick assurance that we are in the proper 3-D space.” This, in turn, puts Falcon 9’s launch and Dragon’s orbit in their proper position in space. Verisurf (714) 970-1683 www.verisurf.com

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CASE STUDY In its pre-launch application at Meyer Tool, one Renishaw Equator gage has eliminated at least four costly hard gages in a new work cell. Source: Renishaw plc

offered a pre-launch trial, Easton and SPC (statistical process control) Manager Bridget Nolan says they immediately recognized its potential. “We got involved with Renishaw’s introduction of the system and provided parts,” Nolan says. “Renishaw programmed them, and the results matched our coordinate measuring machine (CMM) results, whose group sets up, maintains and programs the company’s gages, fixtures and instruments.”

SAVING MONEY WITH

COMPARATIVE GAGES Aero-engine component maker Meyer Tool lowers hard gage costs with the software-driven Equator gage.

A

software-driven comparative gage— CUTTING THE COST Renishaw’s (Gloucestershire, UK) OF HARD GAGES Equator system—is already starting to For in-process dimensional measuresoften up the cost for numerous hard ment, Meyer Tool principally relies on gages at aero-engine component maker work-cell-based point-to-point contact Meyer Tool Inc. (Cincinnati). In its gages, using pneumatic digital probes. pre-launch application, one Renishaw Hard gages in the machining cell give Equator gage has eliminated at least four fast feedback but are expensive. Design/ costly hard gages in a new work cell. The build of the part nest can cost $6,000, company’s custom hard plus probes at more than $500 each, gages can cost up to $20,000 as well as verification BENEFITS each to design, build and studies and maintenance, » The Equator uses touch and maintain, according to Beau Easton explains. “If we scanning probes, styli and Easton, quality manager at are producing a makestylus change racks and the company. complete nozzle, there programming software. Meyer Tool designs, could be six to 10 fix» Cost-wise, three to five builds and maintains doztures, each with six to 20 hard gages in a Meyer ens of these costly gages probes, and if a feature Tool work cell can all be every year for in-process or tolerance on the part replaced by one Equator. measurement. Down the changes, it adds time for » The Equator can be used line, design changes on the gage to be altered and for multiple parts, switching a part can add another verified,” he says. between them in seconds, $3,000 to $10,000 to reconWhen shown as well as reprogrammed figure and qualify an existRenishaw’s Equator for many other parts over ing gage. comparative gage and its life.

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COMPARATIVE GAGING, MASTERING AND REPEATABILITY The Equator system uses the comparison method of mastering and measuring familiar to anyone who uses dedicated gaging systems. A master component with features of known dimensions is used to “zero” the system, with all subsequent measurements compared to this part. The key to the Equator system is a highly repeatable and radically different metrology mechanism based on a parallel kinematic structure. This mechanism is lightweight, allowing rapid motion, yet very stiff and repeatable. The system uses Renishaw touch and scanning probes, styli and stylus change racks, and Modus Equator programming software. Cost-wise, three to five hard gages in a Meyer Tool work cell can all be replaced by one Equator—and the Equator can be used for multiple parts, switching between them in seconds, as well as reprogrammed for many other parts over its life. ASSIGNED TO A LEAN CELL The first Equator system is currently assigned to a lean machining cell in Meyer Tool’s shop. Demonstrating its adaptability, it integrates with Meyer’s Orion SPC system, maintaining a familiar look for machinists and shortening the learning curve. Orion communicates with the Equator’s Modus software, presenting the operator with results in the form of dimensional data and SPC charts that allow the operator to determine computer numerical con-

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Equator measurement results are presented as variable data so the machinist can compare the current part with recent measurements, rather than get a simple pass/fail result. Source: Renishaw plc

trol (CNC) offsets. “Keep in mind, the machinist sees variable data and can compare the current part with recent measurements, so it’s not just a pass/fail determination,” Nolan explains. “The parts must meet tolerances of ±0.001 to ±0.003 inch. Inspection time varies with the part but typically takes two to six minutes, well within the TAKT time of the cell, so the system easily keeps pace with machining operations.”

Design changes on a part can add another $3,000 to $10,000 to reconfigure and qualify an existing hard gage, while Equator can be reprogrammed to accommodate part changes. Source: Renishaw plc

facilities, Meyer Tool recognizes the potential cost advantages of a flexible, software-driven gaging system. “We are still expanding our knowledge and capabilities with the Equator system, but have high expectations it will ulti-

mately alleviate a large part of our cost burden for hard gages,” Easton adds. Renishaw Plc (847) 286-9953 www.renishaw.com

MEASUREMENTS TRACEABLE TO ABSOLUTE CMM STANDARDS The Equator measurements at Meyer Tool are correlated with those from a CMM, using a CMM-calibrated master part. “The master part sets the values the Equator expects to find inside its measuring envelope while the software automatically applies the compensation values from nominal taken by the CMM,” Nolan explains. “It must check within 10% of allowable tolerance from nominal.” There is no need to remaster on every part change, though Meyer does remaster on a three-hour schedule to compensate for changes in the plant’s temperature. “The Equator system memorizes the master parts and validation scores, so we can switch parts as many times as needed during the three-hour window, and not have to remaster,” Nolan says. THE SOFT SOLUTION TO HARD GAGE COSTS With more than 100 hard gages costing $10,000 to $20,000 each throughout its

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HAWKEYE VIDEO BORESCOPES GO ANYWHERE! Hawkeye Video Borescopes are the perfect choice for completely portable inspection and easy image capture. Quickly inspect machined parts, castings, welds, and more, with the image quality of video and the flexibility of 2- and 4-way articulation. These scopes deliver 5X higher image quality than fiber optic borescopes.

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MICRO EPSILON OFFERS THE WORLD'S SMALLEST INFRARED IMAGER FOR PROCESS CONTROL OR TEST AND MEASUREMENT. Key specifications: • Sensing range: -20C .. 900C • USB interface • High Speed Frame rate: 120Hz • Process I/O interface A sophisticated software package gives you maximum flexibility for the most versatile use.

Micro-Epsilon America 8120 Brownleigh Dr. Raleigh NC 27617 Tel.: +1 919 787-9707 www.micro-epsilon.com

HIGH QUALITY MEASUREMENT TECHNOLOGY Fischer Technology is a U.S. manufacturer and leader of coating thickness measurement, material testing, and material analysis instrumentation used in industries from aerospace to solar. Test methods include: X-ray fluorescence • Eddy current • Magnetic induction • Phase-sensitive eddy current Coulometric • Beta backscatter • Micro-hardness

Fischer Technology, Inc. (860)683-0781 info@ﬁscher-technology.com www.ﬁscher-technology.com

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

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

4XDOLW\0DQDJHPHQW6RIWZDUH Intelex Quality Management Software enables effortless ISO 9001 conformance. • Enable anyone, anywhere, at any time to submit, store and access data. • Automatically tabulate and generate audit reports. • Ensure ongoing, stress-free preparedness for internal and external quality audits. • Streamline data collection processes with task management and email notifications. • Get a 360-degree, real-time view of your quality program from a comprehensive dashboard.

www.intelex.com | [email protected] | 1-877-932-3747 Contact us today for a free trial of this or any of our other quality management software.

www.qualitymag.com

June 2011 | QUALITY

47

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QUALITY | June 2011

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

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STYLI AND ACCESSORIES FROM CARL ZEISS • Large selection and great prices on M5, M3, and M2 styli and other popular accessories. • Over 500 products in stock and available for same-day shipping. • Find styli fast using new convenient search tools: shop by size, material, length, and sensor type.

www.zeissmetrology.com Carl Zeiss Industrial Metrology 6250 Sycamore Lane North Maple Grove, MN 55369 (800) 327-9735

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

Hexagon Universal Calibration Services www.HexMet.us/qshucs 248-449-9508

JUMP OUT OF THE CMM QUEUE! Make fast Go/No Go decisions with the ShapeGrabber Ai310 industrial 3D scanner. It rapidly scans small to medium, complex-shaped parts, getting you quickly back into production. Improve quality delivery and reduce inspection time by hours with this very fast, integrated and easyto-use scanner.

TESTING & ASSESSMENT SERVICES ShapeGrabber Inc. W: www.shapegrabber.com T: 1-(613) 247-1707 E: [email protected]

TUVRheinland®—a leader in testing and certification services since 1872 and a Nationally Recognized Testing Laboratory with 300 locations in 60 countries—helps manufacturers get their products to global markets quickly and cost-effectively.

For a free brochure on the company’s testing and assessment services visit www.tuv.com or call 1-TUV-RHEINLAND (1-888-743-4652).

CALL SUNNY COVERLY AT (610) 932-8350, OR FAX: (248) 283-6587 www.qualitymag.com

June 2011 | QUALITY

49

QUALITY

PRODUCTS THE LATEST PRODUCTS TO HELP YOU IMPROVE YOUR MANUFACTURING PROCESS

PORTABLE MEASUREMENT ARM The Faro EdgeArm is a portable measurement arm that allows manufacturers to verify their product quality by performing inspections, tool certifications, computer-aided design (CAD)-to-part analysis and reverse engineering via hard probing and noncontact laser scanning. It has an integrated personal measurement assistant, a built-in touch screen and onboard operating system, and standalone measurement capability. A laptop is no longer needed to perform quick and simple dimensional checks, or to optimize system performance with on-board diagnostic routines. FARO TECHNOLOGIES (800) 736-0234

COMPACT TACHOMETER

WWW.FARO.COM

The HT-4200 tachometer weighs less than 4.5 ounces and has an LCD. The HT-4200’s light beam has a range of 12 inches, with a measurement accuracy of 1 revolution per minute (rpm). The device can measure up to 50,000 rpm and measurement setup involves applying a small piece of reflective tape marker or reflective paint to the surface of the object being measured. The tachometer was designed for use in areas with space restrictions and safety concerns.

ABSOLUTE GAGING PACKAGE The no-drift Absolute Gaging Package is made up of the Acanto Absolute Length Gage with the ND 2100G Gage-Chek metrology readouts. This gaging package was designed for fixed gaging applications. The Acanto has optical encoder capabilities and resolves gage drifting, linearity over the entire measuring range or referencing upon startup. The Acanto’s measuring principle does not drift over time, nor does it require mastering. Two microns of accuracy are held throughout the entire measuring length. It comes in both spring-operated and pneumatically-operated models.

ONO SOKKI (630) 627-9700 WWW.ONOSOKKI.CO

HEIDENHAIN | (800) 233-0388 | WWW.HEIDENHAIN.COM

DOCUMENTATION SOFTWARE The TrackerCal 4 software package has a PDF-based reporting capability which has documentation suitable for traceability requirements, presentations or internal cost justification needs. It has a graphic interface that leads the operator through setup to calibration and readies the laser tracker for use. It has diagnostics with password protections. AUTOMATED PRECISION INC. (800) 537-2720 WWW.APISENSOR.COM

SIMULATION PROCESS SOFTWARE Isight 5.5 provides designers, engineers and researchers with an open system for integrating design and simulation models—created with various computer aided design (CAD), computer aided engineering (CAE) and other software applications—to automate the execution of up to thousands of simulations. Isight optimizes products against performance or cost metrics through statistical methods such as Design of Experiments (DOE) or Design for Six Sigma. DASSAULT SYSTÈMES | (800) 382-3342 | WWW.3DS.COM

50

QUALITY | June 2011

www.qualitymag.com

MULTISENSOR METROLOGY SYSTEM The HN-6060 is a noncontact inspection system that has laser scanning capabilities, five-axis synchronized hardware control and can inspect complex shapes including gear teeth, turbine blades and appliance housings. The metrology system’s laser scanner and shape from focus (SFF) sensor uses active texture projection to measure shapes even with glossy surfaces or no surface texture. Touch probes and optical heads have TTL laser AF, which allows it to perform shape measurements of parts such as complex automotive and machined components, molded parts and medical devices.

FOUR-AXIS RECEIVER The four-axis Microgage Receiver has alignment information for evaluating and correcting machinery alignment problems. The 4-D receiver measures two linear axes—X and Y—and their two angular components yaw and pitch. The two linear axes show how well machinery is aligned along a common centerline and the angular readouts show if parallelism problems are present. It was designed for aligning lathes, turning centers and spindles, as well as moving linear slides, rams and pistons, injection molding machinery and moving mechanical subassemblies.

NIKON METROLOGY

PINPOINT LASER SYSTEMS

(810) 220-4314

(800) 757-5383

WWW.NIKONMETROLOGY.COM

WWW.PINLASER.COM

QUALITY MANAGEMENT SOFTWARE The Reliance 8.0 is enterprise quality and compliance management software for identifying, mitigating and preventing high-risk events through integration, automation and collaboration. It has a SharePoint integration feature; a production part approval process to aid suppliers in complying with customer specifications; a failure mode and effects analysis module; and the capability to run test scripts. ETQ INC. (800) 354-4476 WWW.ETQ.COM

DATALYZER International Partners in Continuous Improvement

418+&+0)24#%6+%#.5*12(.11451.76+105T 1/24'*'05+8'51.76+105(14;174# %1..'%6+10X#0#.;5+5#0&4'2146+0)0''&5T 10+6146*175#0&51(241%'55'5#6#).#0%' 10#%1.14g%1&'&56#6755%4''0T 7.6+g.#0)7#)'5722146T 7221465+%4151(6'48'4X4#%.'#0& +%4151(6%%'55#$#5'2.#6(14/5T '#.g6+/''/#+.#0&6':6/'55#)'#.'46510 75'4g%10(+)74#$.'%10&+6+105T #56#0&'#5;+/2.'/'06#6+10#0&72'5T Since 1981, DataLyzer International has been providing personalized service to the ever-changing international market, including automotive, semiconductor, medical, military, food processing and packaging, and emerging technologies, such as solar and high-tech plastics.

www.datalyzer.com www.qualitymag.com

June 2011 | QUALITY

51

PRODUCTS

3-D WHITE LIGHT MEASUREMENT SYSTEM The manual measurement system Cognitens WLS400M and the automated measurement system Cognitens WLS400A are available in portable configurations and automated systems and can be operated with all common industrial robots. The WLS400 uses digital stereo vision technology to generate 3-D data pertinent to automotive and aerospace applications. The WLS400’s can shoot and capture 3-D surface data in less than 10 milliseconds, and any vibration in frequencies up to hundreds of hertz do not affect the results. The device’s performance also is not impacted by variable lighting or temperature changes.

TOUCH PROBE SYSTEM

HEXAGON METROLOGY

MARPOSS

+33 (0) 38150 4800

(800) 274-9433

(248) 370-0404

WWW.DIGITALSURF.FR

WWW.HEXAGONMETROLOGY.US

WWW.MARPOSS.COM

52

QUALITY | June 2011

The WRS is a touch probing system with radio transmission for worldwide use. It is comprised of a wireless touch probe, wireless tool setter and wireless bore gage, all of which communicate via a single radio frequency (RF) receiver. The system can be used on medium-tolarge-sized machining centers and mills. It has 2.4 gigahertz transmission frequency, spherical transmission characteristics and 15-meter operating range. The system was designed for part set up and inspection on large machines. No line-of-sight is necessary between the receiver and transmitter.

IMAGING SOFTWARE MountainsMap 6.1 is the newest version of the MountainsMap surface imaging and analysis software for surface metrology instruments, including confocal microscopes, white light interferometers and scanning probe microscopes. It has calculation speeds up to 16 times faster than in MountainsMap 5.1; second-generation lead analysis for the automotive industry and co-localization of images of the same surface generated by different instrument families. DIGITAL SURF

www.qualitymag.com

WHITE LIGHT MULTISENSOR MEASURING MACHINE The O-Inspect multisensor measuring machine inspects complex parts for the electronics and plastics industries, for medical and automotive technology, and precision engineering. The workpiece is illuminated with bundled white light. A spectrometer analyzes the reflected light and determines which color has the highest intensity. The measuring machine can determine the distance from the sensor to the surface using spectral color—and derives the exact topography of the part from this information. The results are displayed using CAD-based Calypso measuring software. It enables extensive size, form and position measurements with systematic user guidance and makes deviations visible and quantifiable.

CALIBRATION MANAGEMENT SOFTWARE

POCKET MICROSCOPE

Manual MET/CAL software calibrates dimensional and mechanical instruments, machine tools and torque gages. It is compatible with fluke calibration MET/TRACK software, so all calibration assets can be kept in the same database. Version 2.1 supports French, German, Italian, Portuguese and Spanish languages; has a hibernation of calibration feature, enables calibration tests, reports and certificates; captures measurement uncertainty and test uncertainty ratio (TUR) values; performs batch calibrations and saves calibration results in a database.

Aven pocket microscopes are designed for quality inspection of parts in tight spaces. The 5-inch instrument magnified a part to up to 50 times its size. It is battery-operated, available with or without a measurement scale and has a glass lens and plastic-aluminum body. A beveled, clear base lets ambient light supplement the LED enhancement.

METCAL

(734) 973-0099

(714) 799-9910

WWW.AVENINC.COM

AVEN INC.

WWW.METCAL.COM

CARL ZEISS INDUSTRIAL METROLOGY (800) 327-9735 WWW.ZEISS.COM/METROLOGY

Compression Tension l

Mechanical & Digital Force Gauges Manual & Motorized Test Stands Wide Variety of Attachments

Calibrate Electric Drivers & Air Tools Digital Torque Screwdrivers & Wrenches ISO9001 & ISO/IEC 17025 Accredited

800-373-9989

L FORCE DIGITA GAUGE

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Imada, Inc.® 3100 Dundee Rd., Suite 707 Northbrook, IL 60062 847-562-0834 Fax: 847-562-0839

4/6/11 10:28 AM

June 2011 | QUALITY

53

LISTEN TO THE LATEST INDUSTRY NEWS WITH Q-CAST Q-Cast Podcasts feature the latest news and information for quality test and inspection professionals—all in a bi-monthly newscast format that you can download to your computer or listen to directly from Quality Magazine’s Web site.

Visit www.qualitymag.com

CL ASSIFIED PRODUCTS

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

SERVICES

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June 2011 | QUALITY

55

ADVERTISING INDEX ADVERTISER

155 N. Pﬁngsten Rd., Suite 205

PAGE

WEB SITE

Automated Precision Inc.

33

www.apisensor.com/domore

Bal-tec Division, Micro Surface Engr. Inc.

33

www.precisionballs.com

Cybermetrics Corp.

BC

www.cybermetrics.com

Datalyzer International

51

www.datalyzer.com

Deltronic Corp.

45

www.deltronic.com

Electro Arc Mfg. Co.

12

www.electroarc.com

5

www.hommel-etamic.com

Imada

53

www.imada.com

InﬁnityQS International

27

www.inﬁnityqs.com

LaVezzi Precision Inc.

32

www.lavezzi.com

Magnescale

25

www.mgscale.com

1, 12, 23, 51

www.mahr.com

Deerﬁeld, IL 60015

GROUP PUBLISHER

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

REGIONAL MARKETING NEW ENGLAND AND MID-ATLANTIC

Hommel-Etamic America

Mahr Federal Inc.

Barbara Grim 1288 Centerton Rd.

Mark 10 Corp.

7

www.mark-10.com

Pittsgrove, NJ 08318

Micro-Vu Corp.

19

www.microvu.com

Minitab Inc.

15

www.qualitycompanion.com

Mitutoyo America Corp.

IFC

www.mitutoyo.com

NCSL International

52

www.ncsli.org

Optical Gaging Products

13

www.ogpnet.com

Origin Technologies Corp.

22

www.origintech.com

Perceptron

41

www.perceptron.com/helix

Q-Das

31

www.q-das.com

Ram Optical Instrumentation

22

www.ramoptical.com

MIDWEST, SOUTHWEST,

Renishaw

39

www.renishaw.com

WEST AND NORTHWEST

Resec Systems Inc.

26

www.resecsystems.com

9

www.stindustries.com

11

www.ssi.shimadzu.com/testing

3, 17, 43

www.starrett.com

UBM Canon

37

www.qualityexpo.com

Werth Messtechnik GmbH

10

www.werthinc.com

Western Gage Corp.

26

www.westerngage.com

Phone: (856) 358-4800 FAX: (856) 358-0900 [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]

Buck Bicek 5820 Middaugh Ave. Downers Grove, IL 60516 Phone: (630) 971-0904

S-T Industries Inc. Shimadzu Scientiﬁc Instrument Starrett Co., The L.S.

FAX: (248) 502-1086 [email protected]

INSIDE SALES INSIDE SALES MANAGER

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]

56

QUALITY | June 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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A Special Section to

Magazine

June 2011 www.ndtmag.com

nondestructive testing including materials test

The Evolution of

Acoustic Inspection p. 12 Eddy Current Validates Critical Heat Treat Processes p. 8NDT

NDT

June 2011

DEPARTMENTS 4NDT

Industry News

6NDT

Back to Basics Create a Good Pipe Radiograph for Wall Thickness Measurement

16NDT Tech Showcase Leak Detection at Its Finest

18NDT NDT Applications Phased Array in Real Time

Source: Criterion NDT

20NDT Products 24NDT Advertising Index EDDY CURRENT

8

Eddy Current Validates Critical Heat Treat Processes The nondestructive testing technique inspects 100% of production line parts.

IN THE NEXT ISSUE Magnetic Particle Inspection Fatigue Testing Crack and Welding Testing

IMAGING

12 The Evolution of Acoustic Inspection Considering the many uses of APR in the academic world, it was only a matter of time until it was discovered by the industrial world.

eXtra Testing Wind Turbines with Radiography

ABOUT THE COVER

12

Operators use acoustic-based inspection technology to perform ultra-fast tests on heat exchanger tubes. Source: AcousticEye

Source: AcousticEye 2 NDT ● JUNE 2011

NDT SPECIAL SECTION

www.ndtmag.com

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

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

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

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

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

UV-absorbing spectacles included

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Modular NDT LED Inspection System

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

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

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

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

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

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

FAA Orders 737 Inspections for Cracks YUMA, AZ—The Federal Aviation Administration (FAA) has arranged inspections of all early model 737 planes after a large hole recently appeared in a Southwest Airlines jet. Boeing said it also is readying a service bulletin for lap-joint inspections on certain 737-300/400/500 airplanes. The FAA’s order applies to approximately 175 aircraft worldwide, 80 of which are registered in the United States.

Most of those planes belong to Southwest, the FAA noted. The “repetitive electromagnetic inspections for fatigue damage” will focus on “specific areas of the aircraft fuselage” on planes that have more than 30,000 flight cycles. Inspections will be repeated at regular intervals. Boeing and National Transportation Safety Administration inspectors are conducting nondestructive testing of

both lap joints on the Southwest Boeing 737-300 that made an emergency landing in Yuma, AZ, after a 5-foot-long hole tore open in the passenger cabin roof area shortly after takeoff. Three more Southwest Airlines jetliners were later discovered to have small, subsurface cracks that are similar to the cracks suspected of playing a role in the fuselage tear of the Boeing 737-300.

Frost & Sullivan: Higher Standards of Quality Provide Opportunities for X-Ray Inspection Systems

Despite the increasing applications and growing need for greater productivity, quality and accuracy of inspection, the global economic downturn has caused end users to scrutinize maintenance and inspection budgets. Although there are numerous advantages offered by digital X-ray, customers’ unwillingness to move away from tried-and-tested techniques—such as film-based inspection—restrains short-term market growth potential and leads to limited investment in new technologies. “Although the transition to a filmless future is a continuous and ongoing trend in the X-ray inspection market, film continues to play a crucial role in meeting the nondestructive testing needs of customers,” notes Mathew. “Particularly, in such trying economic conditions, companies with lower financial resources are unwilling to make large investments in digital radiographic technology.”

As Canada’s national nonprofit membership based society for the people and companies engaged in the business of nondestructive testing (NDT), the Canadian Institute for NDE has for more than 30 years delivered training for NDT and operated a governmentapproved certification test center, while also providing a host of other member services to ensure NDT professionals and practitioners can network, stay abreast of new technology and industry news, and improve their knowledge. Cote joined the CINDE in 2007 as a project manager and was promoted to managing director in 2010. Prior to that he worked for 30 years at Dofasco Inc. and also worked as a training instructor for more than 20 years, delivering a variety of continuing education and full-time courses for Mohawk College and Northern College in Ontario and Northern Lakes College in Alberta.

SAN ANTONIO, TX—Analysis from Frost & Sullivan’s world X-ray inspection systems market finds that the market earned revenues of $344.2 million in 2009 and estimates this to reach $450.6 million in 2014, saying the rising standard of quality and safety of critical structural components are expected to bring in the revenues. Recent industrial disasters such as the oil spill in the Gulf of Mexico have placed the spotlight on the need for stringent quality control programs. Reacting to such incidents, governments across the globe have announced plans to strengthen laws to prevent industrial debacles. “The aerospace industry, in an effort to fulfill high standards of safety and quality, has traditionally been the first to adopt the latest advances in X-ray technology intended for the field of medicine,” says Frost & Sullivan Industry Analyst Vijay Mathew. “Examples of these advances are high- volume, safety-critical inspection applications, repair and maintenance applications and precision three-dimensional material analysis.” Apart from rising usage in key enduser industries such as aerospace, oil and gas and automotive, new application areas such as food safety inspection hike the demand for X-ray equipment. 4 NDT ● JUNE 2011

Canadian Institute for NDE Appoints New President HAMILTON, ONTARIO, CANADA— The Canadian Institute for NDE (CINDE) has promoted Larry Cote, CET, CLS, CMRP to president and CEO, reporting to the chairman of the board. In his position, Cote will work closely with the executive committee and the board to pursue the goals set out in the CINDE strategic plan.

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Exova Expands Testing Facility BRIDGWATER, SOMERSET, ENGLAND—Exova has expanded its fatigue testing capabilities for composite and metallic materials to growing customer demand, particularly from the aerospace sector. During the last quarter of 2010 three servo hydraulic test frames were acquired and commissioned at its Bridgwater, Somerset, site. Following a successful audit in March 2011, Exova was awarded UKAS www.ndtmag.com

Carestream Raises Prices of X-Ray Films ROCHESTER, NY—Carestream Health is increasing the prices of its medical, dental, and nondestructive testing films worldwide. Prices will increase as much as 50% or more in some areas of the world. The increase is due to ongoing rises in the cost of commodities used in film manufacturing, including silver, polyester and other essential resources, according to the company. www.ndtmag.com

Silver, which comprises a major portion of manufacturing expenses, has more than doubled in cost in the last year and has increased more than five times in cost in the last six years, Carestream says. In addition, oil prices have risen 30% in the last year, which heightens the cost of utilities, transportation and the

petroleum-based polyester used in the production of film. Specific details surrounding price increases will be communicated locally in each country. In the interim, customers that have questions are asked to contact their local Carestream Health sales representative or authorized dealer.

©2010 Thermo Fisher Scientific Inc. All rights reserved.

accreditation for a range of composite and metallic international fatigue standards, meaning Exova can now officially begin to carry out fatigue testing for its customers. The Bridgwater laboratory, which works for aerospace primes including Rolls Royce, Airbus and GKN Aerospace, has plans to increase capacity further in the future. Exova Bridgwater specializes in the testing of composite materials, with core services including mechanical, physical, metallurgical and failure investigation. Peter Allen, general manager of Exova Bridgwater, says, “The expansion of our in-house testing capabilities offers customers a full suite of tests across all techniques and material types under one roof. “This is an important development for Exova, and forms part of the Aerospace division’s long-term strategy, which includes plans for further expansion of our global testing facilities and capabilities in the future,” he adds. Current capacity of the new frames is up to 250,000 N in tension and compression each with integrated strain and temperature monitoring. The frames have initially been set up with a bias toward flat samples which lend themselves to composite testing. Complementing existing capabilities the initial projects are making use of the established machining, tabbing and impacting facilities already at Bridgwater by testing ‘fatigue after impact’ test specimens at various R-Ratios on CFRP. A single and double lap shear program is also utilizing the large capacity grips, which enable gripping of considerably thicker samples.

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Create a Good Pipe Radiograph for Wall Thickness Measurements Whether it is gamma or X-ray, profile shots can be optimized for accurate wall thickness measurements. By Steven A. Mango A common application of computed radiography for nondestructive examinations is profile shots for the in-service inspection of piping for erosion and corrosion. This involves a side view of the pipe with one or both outside walls visible, allowing the inspector to visualize and measure the wall thickness to characterize deterioration from erosion or corrosion, or a buildup of scale and deposits. Because of the nature and location of in-service piping, such shots are commonly done with portable gamma sources, favored in field-radiography applications because of their mobility, portability and self-contained nature. Furthermore, the high energy of gamma sources often is required to penetrate the path length along the tangent to the inner pipe wall, especially with increasing pipe diameters. Although not as common, X-ray sources also are used, particularly in applications involving smaller diameters and thinner walls. To facilitate reliable measurements, the radiograph must accurately record the locations of the outside and inside walls of the pipe. While image quality requirements are not particularly demanding for wall thickness measurements, the exposure must be controlled such that there is sufficient penetration to image the inside wall, but not so much that the background of the image is saturated, compromising the location of the outside wall by “undercut.” Normally, this is not an issue when using gamma sources because the absorption of storage phosphor imaging plates is relatively inefficient at such high energies, and it is difficult to saturate the background. On the other hand, the imaging plates are very efficient at absorbing lower (X-ray) energy, and the background can easily be saturated. A good rule of thumb for the background is not to exceed about 80% of the available dynamic range (maximum 6 NDT ● JUNE 2011

Figure 1. Source: Carestream Health

Figure 2. Source: Carestream Health

intensity) of the image. Let’s consider the two most common imaging modes. For a 16-bit linear image with a maximum pixel value of 65,535, the background should not be more than about 52,000. That’s easy: 80% of 65,535 is about 52,000. For a 12-bit log image with a maximum pixel value of 4,095, the background should not be more than about 4,000. How and why 4,000 is 80% of 4095 is not obvious to those who do not “think” in logarithms. There are two basic ways in which an inspector measures wall thicknesses on a pipe radiograph. In the most rudimentary method, the viewing software allows the inspector to calibrate a ruler to a known reference in the image, then use that ruler to make measurements based on visual observations and determinations of the inside and outside wall boundaries. This requires not only an accurate radiograph, but also an accurate display on the monitor. Any errors in the window (contrast)

and level (brightness) adjustments could easily result in misperceptions of where the wall boundary actually is, and hence erroneous measurements. Fortunately, most viewing software also features more sophisticated measurement options whereby the measurement tool is performing the analysis on the underlying data, and not dependent on the display or the inspector’s ability to locate the wall boundaries. In either case, though, the radiograph must accurately capture the precise locations of the pipe’s inner and outer walls to facilitate accurate measurements. Now, let’s follow a couple of examples showing a gamma shot, a poor X-ray shot and a simple technique to produce a nice X-ray shot suitable for measurements. First, let’s look at a baseline image. Figure 1 shows a gamma shot with good overall exposure, good delineation of wall boundaries and a background intensity well below saturation. Properly

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yields a measurement accuracy of 99.1%. Note that the extra copper filtration even cleans up the inside wall boundary, so accuracy is improved all around. Whether it is gamma or X-ray, profile shots can be optimized for accurate wall thickness measurements. All it

takes is a little common sense and a few millimeters of copper. Steve Mango is the worldwide technical manager, NDT Solutions at Carestream Health Inc. (Rochester, NY). For more information, call (585) 627-6523, e-mail steven. [email protected] or visit www.carestream.com.

Figure 3. Carestream Health

calibrated for length, a wall thickness measurement tool yields a result with about 98.5% accuracy on this image. Figure 2 is an X-ray shot, made with a typical combination of copper screens of 10-mil, front and back, inside the cassette, but no tube filtration. While the image appears suitable, note that the background is saturated, with a pixel value of 4,095. In this case, the saturated background compromises the outside wall boundary, resulting in a measurement accuracy of only 90.7%. While this may be considered accurate enough for some applications, it can certainly be improved. If using X-ray as the source for profile shots, how does one limit the background intensity and make the image look more like a gamma shot? The answer is not really a secret, and in fact is a simple technique familiar to many radiographers: pre-filtration at the tube. A few millimeters of copper at the tube will filter out the low energy portion of the X-ray spectrum, effectively “hardening” the beam. This leaves the higher energy portion of the beam to effectively penetrate the specimen, but eliminates the low energy portion that would easily be absorbed by the imaging plate, resulting in background saturation. The result is shown in Figure 3, in which 4 millimeters of copper at the tube reduced the background to well under saturation and www.ndtmag.com

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JUNE 2011 ● 7 NDT

Eddy Current V Heat Treat

PRODUCTION The nondestructive testing technique inspects 100% of production line parts.

components they procure. As heat treat process variations are not easy to detect visually, it is often something that is assumed to have been done correctly when evaluations are performed by production sampling of parts.

By Joe Jessop

O

On Ja January 17, 2011, General Motors announced that hat iit was recalling more than 26,000 vehicles due axle cross pin. The models affected to o a defective d included Cadillac, Chevrolet Colorado, Silverado, inclu nclu Tahoe Taho and Yukon. These vehicles were built with cross pins that may not have been heat rear axle a treated, and as a result, could fracture and/or move out of position. If this were to happen, the rear axle could lock up while driving and potentially cause an accident. This example highlights the impact that a relatively inexpensive, improperly manufactured, yet safety critical component can have on an automobile, aircraft or medical device. Due to the nature of today’s global supply chain, it is critical that subassembly manufacturers and end vehicle manufacturers have confidence in the

A major automotive component manufacturer wanted to validate the heat treatment of speciﬁc locations in its line of water pump shafts. These areas required speciﬁc hardness in wear areas, but a softer material in other areas was needed in order to maintain the strength of the shaft. The manufacturer wanted to inspect 100% of their parts. Source: Criterion NDT 8 NDT ● JUNE 2011

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Eddy Current Heat Treat Validation Eddy current is a mature, nondestructive testing technique that is used to validate the correct material structure of a conductive component. Material structure validation looks for variations in heat treat conditions, alloy compositions and defects in the material such as crack and flaws. Modern eddy current test systems can validate the heat treat conditions of components very quickly, which allows it to keep up with production line speeds. This makes it an effective test for validating 100% of the manufactured components. This is more effective than only using sample testing, which is done after the production parts have been manufactured.

How Eddy Current Heat Treat Validation Works Eddy current is an electromagnetic test that looks at how electrical currents f low in a metallic structure or component. These currents will f low differently in metals that have differing material structures. Heat treating changes a component’s material structure, which is why eddy current is an effective heat treat test method. Eddy current testing results have shown an excellent correlation with impact testing, such as Rockwell testing. Unlike traditional impact hardness testing, eddy current testing is a comparative test, which compares a known good part vs. a part under test and is www.ndtmag.com

Validates Critical Processes at

LINE RATES the shaft. The manufacturer wanted to inspect 100% of their parts. The solution for the automotive manufacturer was to install an eddy current testing station that would be able to test not only multiple diameters, but also multiple lengths of water pump shafts. The eddy current testing fixture developed for this application contained three independent eddy current encircling coils, which provided the ability to test in three specific areas. A half round piece of black nylon on the side was the “tooling” used to establish the eddy current coil spacing for each pump shaft part number. A titanium center tube provided a guide for the parts preventing wear on the eddy current coils, while having minimal impact on the testing due to its’ low conductivity. This eddy current probe and system is designed to test the proper heat treat of a valve seat, which has a long pin on the probe designed to ﬁt inside the value guide, thereby ensuring proper alignment of the eddy current probe and area under test. Source: Criterion NDT

evaluating a section of the part rather than a specific point on the material. Eddy current instruments generate either a single frequency or multifrequency electrical signal that is sent to an eddy current coil or set of coils. These coils generate an electromagnetic field, which causes eddy currents to flow in the conductive material under test. These eddy currents will flow differently depending on the materials hardness, alloy or existing flaws. The same coils sense the changes in the secondary magnetic field being generated by these eddy www.ndtmag.com

currents and these changes are sent back to the eddy current instrument where it is analyzed and compared to a known good material condition.

Case Study: Eddy Current Water Pump Shaft Testing A major automotive component manufacturer wanted to validate the heat treatment of specific locations in its line of water pump shafts. These areas required specific hardness in wear areas, but a softer material in other areas in order to maintain the strength of

TECH TIPS ● As heat treat process variations are not easy to detect visually, it is often something that is assumed to have been done correctly when evaluations are performed by production sampling of parts. ● Eddy current is a mature, nondestructive testing technique that is used to validate the correct material structure of a conductive component. ● Eddy current testing is a comparative test which compares a known good part vs. a part under test and is evaluating a section of the part.

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As eddy current testing is a relative test, a second set of eddy current coils with a known good shaft was used as an external reference. For this application, the master setup parameters for each of the parts were saved as a unique configuration in the eddy current instrument for comparison. To properly test for heat treatment in three areas at once, the testing had to be accomplished in static mode requiring that the part be momentarily held in the test fixture. The sorting mechanism was built to handle the multiple lengths and diameter of parts. Heat treated water pump shafts would enter the top of the fixture and be metered into the top of the eddy current coil fixture. They would be stopped for approximately 1 second. If the part was accepted, it would be released and automatically go into a good parts bin. Reject parts would go into a reject bin. Testing rates were

This eddy current testing ﬁxture contains three independent eddy current encircling coils, which provided the ability to test in three speciﬁc areas. A half round piece of black nylon on the side was the tooling used to establish the eddy current coil spacing for each pump shaft part number. A titanium center tube provided a guide for the parts preventing wear on the eddy current coils, while having minimal impact on the testing due to its’ low conductivity. Source: Criterion NDT

approximately 40 parts per minute. If multiple rejects were discovered to occur in a row, the eddy current instrument was capable of raising an alarm, notifying plant operators that there could be an upstream process issue. The eddy current testing solution allowed the automotive component manufacturer to inspect 100% of its water pump shafts in very specific locations, at production line rates. This not only ensured top quality of the products they delivered, but also identified when heat treat processes were not working correctly, allowing them to quickly fix the problem and reduce scrap and warranty costs. Onehundred percent testing using traditional indentation methods would not have been possible. As the test fixture was capable of testing numerous diameters and lengths of shafts, the manufacturer was able to save on testing costs and shop f loor space.

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testing methods and indentation methods, such as Rockwell testing. Modern eddy current instruments are easily integrated with material handling systems providing a method to automatically reject bad components at production line rates. In addition, this information

provides real-time information to line operators letting them know if a manufacturing problem exists. NDT Joe Jessop is the president of Criterion NDT (Auburn, WA). For more information, e-mail [email protected] or visit www.criterionndt.com.

To properly test for heat treatment in three areas at once, the testing had to be accomplished in static mode requiring that the part be momentarily held in the test ﬁxture. The sorting mechanism was built to handle the multiple lengths and diameter of parts. Heat treated water pump shafts would enter the top of the ﬁxture and be metered into the top of the eddy current coil ﬁxture. Testing rates were approximately 40 parts per minute. Source: Criterion NDT

Heat Treat Testing of Internal Features Eddy current testing is not limited to heat treat validation of external features or small components. In many cases, key heat treat areas are located in very complex components in very specific areas. This often requires the use of a custom manufactured eddy current probe, which may contain numerous coil windings. These probes often are manufactured with stainless steel housings to resist wear and are designed to work with on-line material handling systems. One example of this is an eddy current probe and system designed to test the proper heat treat of a valve seat. The long pin on the probe was designed to fit inside the value guide ensuring proper alignment of the eddy current probe and area under test. Eddy current testing offers manufacturers a way to validate the heat treat processes that are performed on a component. These tests offer consistent results that are well correlated with destructive www.ndtmag.com

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

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The Evolution of Acoustic Inspection Based on Acoustic

PULSE REFLECTOMETRY Considering the many uses of APR in the academic world, it was only a matter of time until it was discovered by the industrial world. By Dr. Noam Amir

T

Time domain reflectometry (TDR) is nothing Google it, and you get 117,000 hits. TDR new. G ne involves sending a pulse of some type into a in involv medium and measuring any reflections created m mediu somewhere in this medium. It has been used to so somew examine electric cables, waveguides and optical ex exami

Shown is a schematic depiction of (a) the UT sound wave, perpendicular to the tube wall vs. (b) the APR sound wave, parallel to the tube wall. UT inspects one point at a time, whereas APR scans the entire tube with one measurement. Source: AcousticEye 12 NDT ● JUNE 2011

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fibers. Acoustic pulse reflectometry (APR) is a particular case of TDR, where the pulse is an acoustic signal, usually injected into one type of tube or another. APR is not as well known as TDR in general. Googling it gets all of 627 hits. APR has been used in the past for some applications that might appear unusual. For example, one major application has been seismic explorations. This, in fact, is not so surprising. Drilling deeply into the ground is a very expensive operation. If important information about ground strata can be gleaned from carrying out several explosions on the surface and measuring the waves reflected from changes in rock and ground density, so much the better. This type of APR has been around for a long time—since the 1960s at the very least. Another application of APR has been to examine the human airways: the nose, mouth and trachea. These are much shorter than the distances to layers deep in the ground; however, there is understandably a great interest in probing these tube systems noninvasively, to the benefit of doctors and patients alike. This also is a rather old application of APR, with papers appearing on the subject since the 1970s. Finally, during the past few decades, APR has been used quite extensively for the study of musical instruments. The study of wind instruments poses problems that are both similar and different to examining human airways: testing them by invasive means is qualitative and inconvenient, due to bends and valves. Thus, the idea of probing their bore by acoustic means is very appealing. In this context, APR is most often used for “bore reconstruction,” for example, reconstructing the geometrical structure of the bore from the reflected acoustic signals. This has been used www.ndtmag.com

for probing delicate historical instruments, or even for quality control in the manufacture of modern instruments. In the same context, several in-depth studies have been the characterization of the reflections caused by throughwall holes. Though the main motivation might have been to detect leaks in historical musical instruments, these methods serve equally well for through-holes in heat exchanger tubing. In essence, the basic idea behind APR also has been applied to the NDT world: ultrasound testing (UT) is based on a very similar principle. In UT, a pulse of high-frequency acoustic energy is sent into the object being inspected, rather than into space, and reflections are created wherever there is a change in the characteristic impedance. In simple words, the reflections are created by any nonuniformity in the object, which is often an indication of a fault or an edge. The capabilities of these techniques in general are strongly related to the typical wavelengths they employ. Ultrasound, for example, has very short wavelengths, enabling it to distinguish slight variations in tube wall thickness. However, it propagates poorly in most media, severely limiting its range. It is therefore used by focusing the acoustic wave into a narrow beam perpendicular to the object’s surface. Thus, when used to examine pipes or tubes, it can only inspect one small spot at a time,

depending on the beam width. UT has been adapted to perform tube inspection through the use of a rotating beam pulled slowly through the tube. APR, however similar in principle to UT, employs much lower frequencies, with the result that it can propagate to

relatively long distances, but with lower resolution. Most commonly it is used to inspect various types of tubular systems, but instead of propagating the acoustic energy into the tube wall, as in UT, it is propagated into the medium filling the tubes—air, or less frequently, water.

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TECH TIPS ● Acoustic pulse reflectometry (APR) is a particular case of time domain reflectometry, where the pulse is an acoustic signal, usually injected into one type of tube or another. ● APR, similar in principle to ultrasound testing, employs much lower frequencies, with the result that it can propagate to relatively long distances, but with lower resolution. ● APR is gaining recognition and acceptance as a useful tool for heat exchanger tube inspection and heat exchanger tube cleanliness verification.

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This APR inspection tool is composed of a handheld probe and an electronics box with an embedded computer for storage, analysis and display. Source: AcousticEye

Naturally, the first question that comes to mind is: how can APR be used to inspect the tube walls if it propagates the acoustic energy in the air enclosed by the tube, rather than the tube wall itself? The answer is quite simple. If a pulse is injected into a perfectly uniform tube, no reflections will be created until the pulse hits the end of the tube. However, any changes in cross section, whether intentional or caused by imperfections on the inner surface of the tube, will create ref lections. These can then be recorded and analyzed. Considering the many uses of APR in the academic world, it seemed only a matter of time until it was discovered by the industrial world. The question is, of course, how does it measure up?

From science to the marketplace Bringing a viable scientific principle out of the academic lab into the field is always a challenge, certainly so in the crowded field of heat exchanger tube inspection. Several different issues, not all of them technical, must be addressed at the same time for such an endeavor to succeed: 1. Performance 2. Usability 3. Standardization 4. Market acceptance As APR is a tool gaining acceptance in the tube inspection market, it is interesting to examine how its implementation deals with the above issues. 14 NDT ● JUNE 2011

• Performance. Clearly, no technology is a panacea. The relative advantages of APR must be identified in comparison to other technologies, along with the drawbacks, to encourage proper use and avoid unrealistic expectations. Looking at these points in detail: • Internal vs. external defects. As discussed, the acoustic pulse utilized in APR propagates in the medium inside the tube. Since it detects changes on the internal diameter (ID) only, it cannot detect defects on the outer diameter (OD). Through-holes, however, present a “short circuit” to the external atmosphere, therefore creating strong reflections even when they are quite small, from approximately 0.5 millimeter in diameter. Such “pinholes” are quite difficult to detect using other means. • Speed of inspection. APR does not require traversing the tubes with a physical probe, sending a sound wave instead. As such, speed of inspection can be increased considerably, with no danger of probes getting stuck or becoming worn. Inspection is typically several seconds per tube, regardless of tube length. • Tube material and configuration. Another advantage of propagating the acoustic wave in the medium filling the tubes is that it is not influenced by tube wall material, be it ferromagnetic or not, or even graphite or any other nonmetallic material. It also can propagate through u-bends, regardless of the tightness of the bend.

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• Automatic interpretation. APR signatures created by various types of defects are well defined, enabling them to be detected automatically by appropriately designed software. Though there have been some attempts to carry out such automatic detection on eddy current signals, they have not yet achieved widespread acceptance. • Cleanliness. The ability of APR to detect defects is subject to tube cleanliness. Pits or holes covered by deposits will not affect the acoustic wave and will therefore not be detected. On the other hand, APR is very sensitive to blockages, even when they are very small. Various types of fouling, such as sludge, sedimentation and scaling will show up as a multitude of blockages. In this case, APR can be used to quantify fouling, giving extremely useful information on the current status of the tubes and the successfulness of the cleaning process. This is a “blue ocean” application: one for which no other solution existed previously. • Usability. Aside from the performance issue, in an industry in which thousands of tubes must be inspected in as short a time as possible, usability is a major and multifaceted issue. Taking a fresh view from the ground up has enabled APR manufacturers coming out with products to innovate in more than the basic technology. An example is tube sheet mapping: the operator takes a photo of the tube sheet on-site, loading it into the software, which then detects and numbers all the tube-ends automatically. This process takes seconds, avoiding the need for manual mapping or procurement of hard to obtain manufacturer schematics. Furthermore, the software presents this map on screen during inspection, indicating the next tube to be inspected, thus enabling the technician to synchronize his location on the tube sheet with the software. Any contribution to speeding up the inspection process is important—saving several seconds per tube can add up to a savings of several hours for an entire job. In a similar vein, automatic flagging of defects also can contribute to www.ndtmag.com

ATS calibration blocks... a step (block) above the rest. making the inspection process more accurate and effective. Software that can run through measurements of an entire heat exchanger, flag the potential defects and present them to the analyst, makes the process more objective, faster, and far less fatiguing for the operator. • Standardization and market acceptance. In the regulated world of NDT, standardization and market acceptance go hand in hand. In fact, this is a typical chicken and egg problem. Many potential users will hesitate to adopt a technology that does not appear in the ASME/ASTM/ASNT standards, and on the other hand, these organizations are hesitant in initiating a standardization process for a technology that is not in widespread use, particularly if it is backed mainly by a single manufacturer, as new technologies often are.

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For the reasons above and many others, the NDT market tends to be a conservative one, so there is probably no fast track to success in this respect. Patience and persistence have proved fruitful, however, and APR is gaining acceptance in traditional applications and more innovative ones such as analysis of tube cleanliness. The heterogeneity of the worldwide NDT market is an aspect that newcomers can take advantage of: current technologies are strongly entrenched in the developed markets, such as the United States and Europe, which are heavily invested in equipment, training and standardized procedures, and therefore often resistant to change. Developing countries are often more receptive to the adoption of newer technologies. APR has QLT04071ATSNDT.indd 1 been very successful in these markets, arming it with a plethora of proven case studies that are very useful in overcoming resistance in other markets. From its long incubation period in the academic world to becoming an off-the-shelf NDT tool, APR has undergone a process of refinement and adaptation readying it for the rigors of industrial use. It is now gaining recognition and acceptance as a useful tool for heat exchanger tube inspection and heat exchanger tube cleanliness verification, with a steady increase in market-share and a good » Accuracy outlook for further expansion into boiler inspection. NDT

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www.heliumleaktesting.com 800-423-1701 NDT SPECIAL SECTION QLT01114HELI.indd 1

JUNE 2011 ● 15 NDT 12/21/10 3:30 PM

Leak Detection at Its Finest The newest leak detectors are consistently adept at revealing potential equipment hazards. By Genevieve Diesing, Associate Editor Leak detection is a highly effective method for revealing potential equipment hazards. Helium leak testing is a nondestructive form of testing and is performed via a helium mass spectrometer, or an instrument commonly used to detect and locate small leaks. Vacuum testing is done by connecting the test object to the leak detector, removing the object and then spraying helium around it. Pressure testing is completed by pressurizing the internal volume of the object to be tested. The object is then examined for leaks with a probe connected to the leak detector. Read on to learn about the newest innovations in the leak testing field.

Vacuum Instrument Corp/VIC Leak Detection (www.vacuuminst.com) has introduced a new series of helium mass spectrometer leak detectors with touchscreen graphical user interfaces (GUIs) for testing the integrity of vacuum systems and parts using helium leak detection techniques. The touch-screen GUI allows for greater system control and monitoring during system startup and operation. Displays include system status; accept/reject status; system health; setup; calibration and other diagnostic functions. The GUI allows the operator to quickly calibrate the system with the MS-60s built-in leak standard, and perform and view a leak rate in standard view or Big Mode for viewing the panel at a distance. A Chart Mode enables an operator to simultaneously view a strip chart of leak rate, range and set point at a glance. System Diagnostic Mode enables one to monitor several operating parameters, while system set-up screens allow the operator to set up to view all system parameters including crossover points, units of measurement, delays, zero point, amp gain and spec tube function. A stylus pen for making selections on the resistive touch panel also is included with the system. The MS-60 Series leak 16 NDT ● JUNE 2011

The touch-screen GUI allows for greater system control and monitoring during system startup and operation. Source: VIC Leak Detection

detectors allow for greater access to system intelligence to accurately locate and measure leaks in a range of applications. Typical applications include aerospace, medical, automotive, appliance, vacuum and nuclear, as well as a host of others requiring a high level of leak detection sensitivity. With a range of applications from engines to medical devices, the Qualitek mR has established itself as one of Uson’s (www.uson.com) leading products. Two transducer inputs allow the Qualitek mR to accept pressure decay, differential pressure, mass f low and load cell transducers to equip operators with a range of testing options. The touch-screen color graphics display and easy-to-navigate PC style are combined with a rotary scroll and click

The Qualitek mR is a single channel tester designed for high-volume industrial leak and ﬂow testing applications Source: Uson

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navigation device. Qualitek mR features built-in pressure plots and statistics, data storage, compensation and calibration, and a pop-up soft keyboard to facilitate program editing. This leak tester has comprehensive communication options with two USB ports, serial communications port, Ethernet and expandable digital input/output. The Qualitek mR is a single channel tester designed for high-volume industrial leak and flow testing applications such as gas control valves, plastic reservoirs, faucets, automotive lamps and components, medical devices and packaging. A NEMA 12 rated enclosure protects the Qualitek mR, which is situated as standard on adjustable stand, and may be removed for machine mounting and integration if required.

Interlaken

Technology

Corp.’s

(www.interlaken.com) new modular production leak testing systems can be integrated into production lines and work cells or can be used alone. Typical applications include fuel system components such as rails, lines and pumps. Many more applications have been identified in HVAC, aerospace and defense. Standard systems are available for pressures up to 100,000 pounds-per-square-inch. This allows companies to find leaks on high-pressure components in-house during quality control checks that were not previously discovered with testing done at less than operational pressures. The system can be configured with custom, quick-change fixtures for highvolume production or with more universal configurations for research and development work. There are many sensor technologies available such as pressure decay, vacuum decay and mass flow. Interlaken integrates the appropriate sensor technology and can incorporate such capabilities as data collection and analysis, part marking and material handling. www.ndtmag.com

Interlaken’s modular production leak testing systems can be integrated into production lines and workcells or can be used alone. Source: Interlaken Technology Corp.

Interlaken’s control module can communicate with other shop floor control systems via Ethernet, ProfiBus or CanBus.

InterTech Development Co. (www.intertechdevelopment. com) has introduced a new family of leak detectors for both single and multi-channel testing. The M1075Y leak detector family offers an array of features, including input/output control of solenoid valves, which take input from sensors and light curtains and eliminate the need and costs for PLC device additions to test stands. The M1075Y leak detector family Embedded Web pages offers an array of features, includallow operators to moniing input/output control of solenoid valves. Source: InterTech Development Co. tor and access operations remotely, including interactive test parameter updates. Touch-screen operation feature simple and intuitive menu-driven operator controls and graphic displays of test cycles. The detectors have real-time display of all leak test stages and data storage in buffer for up to 1,000 test records, as well as a quick interchange of test sequences for multiple product testing and a Wi-Fi option.

employs Ulvac pumps, valves and gages throughout. The ALT systems are modular in design with most of the major components being manufactured by Ulvac. This modular approach to design enables customization of the system to individual customer requirements, while maintaining as many standard components as possible, providing optimum performance and support. Air-to-air cycling of the ALT system is automatic; components are placed in a vacuum chamber, charged with helium and the chamber is evacuated. A mass spectrometer-based helium leak detector is used to measure a total leak rate for the components to check all leak points to guarantee product quality. Pump systems are sized to evacuate both chamber and test part to a suitable pressure within a short period of time to meet the requirements of desired machine cycle time. The leak detector used is the proven Heliot 700 with a sensitivity to detect helium leaks as small as 1 by 10E-12 millibar-liters-per-second. The factory automation interface with the ALT system can be engineered and supplied by Ulvac as well for integration into the production line. Each system is equipped with a modem link so that system software troubleshooting can be done remotely by a telephone to the Ulvac service center. This capability is useful in enabling remote assistance for faultfinding and completing software changes with minimal delays in a production setting.

Pfeiffer Vacuum’s (www.pfeiffer-vacuum.com) SmartTest, a wireless, remote-controlled helium leak detector, gives fast, reliable results, low detectable leak rates and short recovery time. The RC 500 WL remote control enables an operator to control the process, and all functions can be remote operated up to 100 meters. The measured values can easily be displayed on the 3.5-inch touch screen and stored in an internal memory of the remote control. The detector features the sensitivity in identifying even the smallest leaks; can quantify the leaks; has reproducibility of the measurement and short measurement times. Ulvac Technologies Inc.’s (www.ulvac.com) automatic leak testing (ALT) systems—including the Heliot 700 leak detector— www.ndtmag.com

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JUNE 2011 ● 17 NDT

Phased Array in Real Time Diagnostic Sonar Ltd. benefits from real-time ultrasonic imaging using National Instruments’ LabVIEW software and PXI hardware. Ultrasonic phased arrays have been used for many years for medical imaging, but until recently they have enjoyed limited success in nondestructive evaluation (NDE) due to cost and complexity. Diagnostic Sonar Ltd. (Silicon Glen, Scotland) has been using arrays for real-time imaging in aerospace NDE for three decades. This background has allowed the company to pioneer a major new capability—termed full raw data (FRD) collection and processing—that offers significant benefits to the customer but imposes new challenges for data acquisition hardware and software. Conventional pulse-echo ultrasound array imaging involves phased excitation of a group of elements from the ultrasonic array, with the differential delays between elements matching the differing propagation paths to generate a beam with specific focus and direction. The analogous reception process involves a recombination of the signals from a similar group of elements after appropriate differential delays have

BENEFITS ● The PXI-5105 offers a performance increase, with 12-bit resolution at 60 million samples per second compared to Diagnostic Sonar’s previous system’s 10-bit resolution at 40 million samples per second. ● The PXI-5105 provides high-resolution sampling, multirecord format and a standardized driver interface for LabVIEW, so that Diagnostic Sonar could configure systems to match customers’ performance requirements and budgets. ● The PXI-5105 acquires eight channels, allowing a single module to replace eight individual image acquisition cards. 18 NDT ● JUNE 2011

Each PXI-5105 acquires eight channels, allowing a single module to replace eight individual image acquisition cards and offering a major cost and size reduction. Source: National Instruments

been inserted. These delays can be varied with time so that the receive focus tracks the transmit pulse, a process termed dynamic focusing. The image is composed of a sequence of beams scanned through the area of interest. The operator perceives the performance to be real-time if frame rates exceed 15 hertz. However, area coverage requires significantly greater data rates, with 100 hertz rates routinely achieved. In contrast, the FRD approach collects pulse-echo data from all transmit and receive element combinations and generates the resulting image by postprocessing, permitting dynamic focus on transmit as well as receive for optimum resolution. This new technique also offers several unique processing possibilities, such as non-linear beamforming and backscatter analysis.

Previous System Limitations Diagnostic Sonar’s previous imaging system, FlawInspecta, is PCI-based and uses National Instruments’ (NI, Austin, TX) image acquisition cards with LabVIEW to

NDT SPECIAL SECTION

acquire the nonstandard video format of the ultrasound image data. Diagnostic Sonar chose LabVIEW because it fulfilled the company’s primary requirements: rapid development of simple but powerful user-interfaces, easy control of both off-the-shelf and custom hardware, and real-time image acquisition and processing offered by the NI Vision Development Module. This hardware and software combination was well-suited to the conventional, real-time pulse-echo imaging application. However, the imaging card’s single channel limits the FRD area coverage rate. The only solution was parallel acquisition, but multiple imaging cards for parallel acquisition was cost-prohibitive.

The NI System Solution The solution was to migrate to the new NI PXI-5105 multichannel digitizer/PC-based oscilloscope, which was flexible enough to handle the image format Diagnostic Sonar needed and offered a simple software upgrade path. www.ndtmag.com

the onboard memory is sufficient to hold all the data for transfer once the acquisition is over. The second challenge was the need to reconstruct the data into an image during acquisition. Diagnostic Sonar found the speed of the NI Development Vision Module sufficient to perform this basic imaging on the fly. NI hardware and LabVIEW software had already proved their worth in the current range of Diagnostic Sonar FlawInspecta ultrasound phased array imagers for nondestructive evaluation. Diagnostic Sonar’s new FRD acquisition approach offers many benefits to the customer, but the existing single-channel configuration would result in a significant drop in area coverage rate. The company needed multiple acquisition channels, but the additional cost and size of multiple single-channel cards was not feasible. The PXI-5105 offered a solution that was scalable to customer requirements and has a multi-record capability that provides a simple software migration path.

National Instruments It was essential that all the acquisition cards were tightly synchronized, so Diagnostic Sonar used a NI PXI-7830R in the star trigger slot for the critical timing and control functions previously implemented in customized FPGAs. Source: National Instruments

Each PXI-5105 acquires eight channels, allowing a single module to replace eight individual image acquisition cards and offering a major cost and size reduction. Diagnostic Sonar can implement a 32-channel acquisition system with just four modules. The PXI-5105 also offers a performance increase, with 12-bit resolution at 60 million samples per second compared to Diagnostic Sonar’s previous system’s 10-bit resolution at 40 million samples per second. It was essential that all the acquisition cards were tightly synchronized, so Diagnostic Sonar used a NI PXI-7830R in the star trigger slot for the critical timing and control functions previously implemented in customized FPGAs. With eight channels per module, high-resolution sampling, multirecord format and a standardized driver interface for LabVIEW, the flexibility and modularity of the PXI-5105 provided a rugged system with virtually unlimited channel capability so that Diagnostic Sonar could easily configure systems to match customers’ performance requirements and budgets.

FRD Challenges The FRD approach introduced two major challenges. The first was the order of magnitude increase in data, which could overwhelm the bus transfer capability. The onboard memory of the PXI-5105 provided a buffer so that the transfer constraint was limited by the average rate rather than peak rate. In the event that Diagnostic Sonar exceeds this rate when performing rapid acquisition over a small area, www.ndtmag.com

(800) 531-5066 www.ni.com

Hardness testing the handy way!

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

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

www.proceq-usa.com NDT SPECIAL SECTION

JUNE 2011 ● 19 NDT

Scan Imaging PolyGate is the single-scan imaging of a sample at 50 different depths, or gates, which yields 50 images that show internal features at each depth. In conventional imaging, much wider gates are used

to confine imaging to a single depth of interest such as the die face or lead frame depth. The ability to set multiple gates that are imaged simultaneously during a single scan gives the operator the ability to see internal features at each gate, and to see how features, including defects, change from one gate to the next.

Sonoscan Inc. (847) 437-6400 www.sonoscan.com

Universal Borescope The 4.0 millimeter universal borescope is a modular borescope system with interchangeable optic objectives that allow inspectors to change angles with one borescope. Optics have been improved, resulting in greater luminosity than previous models. The borescope has threaded tips and working lengths from 135 millimeters to 1,460 millimeters. The 4.0 version has improved rod lens optics, brighter images and a larger picture than previous models.

Schoelly Imaging (508) 926-8855 www.schoellyimaging.com can be used for days or weeks in the field before data are downloaded. In addition, it has a corrosion mode that helps identify thinning spots, and MultiECHO technology improves measurement accuracy on uneven surfaces.

CorDEX Instruments

Ultrasonic Handheld Tester The UT5000 measures metal thickness for nondestructive testing on pipes and fixed equipment. It uses radio-frequency identification (RFID) technology to locate and log up to 1,000 measurements, each linked to a specific location, date and time. It also measures metal thickness for nondestructive testing on pipes and fixed equipment within hazardous locations, providing data for developing a predictive maintenance program to improve safety. The device

(877) 836-0764 www.cordexinstruments.com

Shearography System The ISISmobile shearography system has a fully integrated robot interface for an automatic test procedure. The system tests large-surface parts without much documentation. The system provides a spatially accurate image of the part surfaces and assigns each measurement result to the surface data. The system tests various composite components, such as sandwich structures with honey-

comb or foam core, aluminium composite and other compound materials.

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

Flaw Detector The OmniScan MX2 is a phased array flaw detector that with a 10.4-inch LCD touch screen with enhanced text input functionality and easy parameter settings. Its touch-screen interface

X-Ray TDI Camera The C10650-461 is an X-ray time delay integration (TDI) camera designed for nondestructive inspection and testing. It maintains high sensitivity and has higher resolution than standard line scan cameras. It was designed for high-throughput inspections that require high sensitivity and high resolution simultaneously, such as inspection of printed circuit boards, electronic assemblies with ball grid array and surface-mounted components.

Hamamatsu (800) 524-0504 www.hamamatsu.com 20 NDT ● JUNE 2011

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with full screen mode has menu selection, zooming, gate selection, cursor movement and text, and value input. It employs wizards during setup and calibration, a high S-scan and A-scan display refresh rate and a fast pulse repetition frequency (PRF). High-speed data transfer can be achieved with an SD card or through USB ports.

Olympus NDT (781) 419-3900 www.olympus-ims.com www.ndtmag.com

Compression Fixture The hydraulic composites compression fixture (HCCF) was designed to improve specimen handling, enables different specimen geometries to be tested and guarantees reproducible results due to

ogy. It combines sector and linear scanning for NDT inspection. It can be used in aerospace, power generation, oil and gas, and the transportation industries. It has up to 32 T/R channels, compatible with 16/32/64/128-element probes. It can transmit single focusing and receive dynamic

focusing. It has both conventional ultrasonic testing and phased array modes and up to 8 kilohertz repeat frequency for high-speed scanning.

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

exact alignment. The HCCF allows different shapes of specimens to be tested. It is compliant with the Airbus AITM 1-0008 industry standard and also can be used for notch compression tests to AITM 1-0008.

Zwick Roell (770) 420-6555 www.zwick.com

Fiber Optic Borescopes The Hawkeye Pro MicroFlex line is composed of fiber optic borescopes that inspect for burrs, surface finish and other defects inside small components. The borescopes are available at 0.5, 0.9

and 1.5 millimeters in diameter and are the smallest diameter scopes in the Hawkeye line. The borescopes produce images via high-resolution, 10,000 or 30,000 pixel fiber-optic image bundles. The optic fibers also allow these borescopes to have flexible or semi-rigid flexibility, allowing them to reach into narrow, twisting paths.

Gradient Lens Corp. (585) 235-2620 www.gradientlens.com

Portable Phased Array System The CTS-602 is a multichannel flaw detector using phased array imaging technolwww.ndtmag.com

NDT SPECIAL SECTION

JUNE 2011 ● 21 NDT

of samples can be done by absorbance, reflectance, luminescence and fluorescence. Applications include mapping color and intensity variations, film thickness measurements and scanning the surfaces of display components for defects.

Craic Technologies (877) 882-7242 www.microspectra.com

Ultrasonic Measurement System

Microspectrophotometer The 20/20 X UV-visible-NIR microspectrophotometer is designed to nondestructively analyze microscopic features of large displays by being capable of incorporating large-scale sample handling. With a spectral range from the ultraviolet to the near infrared, analysis

The UltraGauge+ ultrasonic wall measurement system can be used by manufacturers to inspect cut-to-length metal tubing. The operator is able to position the tube manually at any location and at any angle. For operator ease-of-use, measurements can be triggered based on a push-button or a foot pedal. The UltraGauge+ system consists of a digital signal processor (DSP) and a transducer fixture; the DSP connects via Ethernet to a PC

running Total Vu software. Current measurement capabilities range from outside diameter of 0.05 inch to 75 inches and wall thickness of 0.011 inch to 0.5 inch, using transducer ranging from 10 megahertz to 30 megahertz depending on the material involved.

LaserLinc (937) 318-2440 www.laserlinc.coma

Non-Destructive Leak IR! M A E US HELIU H WIT

VITY I T I S SEN

4037 GUION LANE INDIANAPOLIS, IN 46268 TL:317-328-8492 www.atcinc.net

Mass Extraction Technology Testing from 1x10-5 scc/sec with patented microflow sensors 22 NDT ● JUNE 2011

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www.ndtmag.com

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Advertiser

Page

Phone

Web Address

Advanced Test Concepts

22NDT

(317) 328-8492

www.atcinc.net

American Society for Nondestructive Testing

10NDT

(800) 222-2768

www.asnt.org

Applied Test Systems Inc.

15NDT

(724) 283-1212

www.atspa.com

Bruker Elemental

7NDT

(800) 366-9956

www.handheldxrf.com

Carestream Health

1NDT

Carl Zeiss Industrial Metrology

11NDT

(800) 327-9735

www.zeiss.com/metrotom

Curtis Industries Inc.

17NDT

(724) 545-8333

www.curtis-test.com

Gradient Lens Inc.

13NDT

(800) 536-0790

www.gradientlens.com

Helium Leak Testing

15NDT

(800) 423-1701

www.heliumleaktesting.com

Instrument Technology Inc.

21NDT

(413) 362-3606

www.scopes.com/v5

Olympus NDT

IFCNDT

(800) 225-8330

www.olympus-ims.com

Proceq USA Inc.

19NDT

(724) 512-0330

www.proceq-usa.com

Spectronics Corp.

3NDT

(800) 274-8888

www.spectroline.com

Thermo Niton Analyzers LLC

5NDT

(978) 670-7460

www.thermoscientiﬁc.com

Yxlon International

BCNDT

(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. 24 NDT ● JUNE 2011

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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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