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september 2008

LC60D - Revolutionizing CMM Laser Scanning

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PRECISION IN MOTION
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CONTENTS

September 2008
News and comment Blisks & integrated measurement
A complex new product development, Blisks, for the huge JSF programme, presents an unprecedented challenge for Rolls-Royce on how to integrate CMM measurement technologies into new manufacturing processes.

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Laser radar in its sights
Janicki Industries utilizes laser radar measurement technology to develop innovative composite tooling for large-scale lightweight prototype aircraft.
Front cover: Metris www.metris.com

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Focus on NIST
The US National Institute of Standards and Technology (NIST) plays a significant role in underpinning US economic and technological development. By Thomas Shattuck

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Editor: Brendan Coyne
Email: brendan.coyne@qmtmag.com Tel: 00 44 1580 715152

Wenzel - the first 40 years
40 Years of Wenzel Precision are being celebrated this year. Strategic acquisitions look set to play a major role in the company’s drive for dynamic growth.

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Media Director: Dawn Wisbey
Email: dawn.wisbey@qmtmag.com Tel: 00 44 208 2897011 Mob: 0044 797 4640371

CMMs Surface and form measurement Micro & nanometrology Global approach to QMS
World leading industrial fasteners company, Anixter Fasteners, has standardised its global quality management system on a single platform solution.

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Website: www.qmtmag.com
Quality Manufacturing Today , published eight times a year, is a print and on-line magazine for the quality, measurement and test industry promoting improvements in manufacturing processes and products through quality control and quality management - from shopfloor to line and enterprise management. Quality Manufacturing Today is published by Cranbrook Media Ltd. Registered company No. 06048241 Registered office: The Coach House, Angley Road, Cranbrook, Kent, TN17 2LE, UK. Printers: Premier Press, Southend © Cranbrook Media Ltd.

Lift off for Burcas
A supply chain development programme based on a six sigma and Lean approach leads to a £1m aerospace contract for Burcas.

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SPC & data collection Food inspection gets better
New inspection X-ray technology developed by European researchers is helping to ensure that the only thing in people’s dinners is the food itself.

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Materials testing Inspex 2008 focuses on quality
Product and feature article enquiries
Log on to www.qmtmag.com for direct links to companies and products featured in this issue.

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Inspex 2008 is the event for the UK’s quality manufacturing professionals to check out the latest in test, measurement and inspection technologies.

www.qmtmag.com

QMT September 08

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NEWS

Applus+ acquires leading US NDT group
Applus+, one of the largest certification companies in the world, has acquired the JanX Integrity Group (“JanX”), a US market leader in non-destructive testing and inspection (NDTI). JanX will be integrated in Applus RTD, the largest NDTI provider worldwide, strengthening its strategic position and increasing its service offering in the US. This operation will allow Applus+ to reach revenues of $100M in the USA. This is the second acquisition since The Carlyle Group, and a consortium led by Caixa Catalunya, took over the majority of the company last November. Applus+ started 2008 by buying MBI, a UK leader in NDT. www.applus.com

Editor’s comment
With all the uncertainty over the economy, caused by the banks and financial sectors collective irresponsibility over sub prime lending on a gigantic scale, it’s great to hear some positive news. I mean Team GB’s medal haul in the Olympics. The best for over a hundred years and fourth in the medal table behind China, USA and Russia, but ahead of Germany, Japan, France and Italy.. Why did it take so long? Perhaps the difference this time was that the UK thought strategically, put in investment and promoted a culture of improvement and self belief - all things which can be directly translated into the competitive manufacturing arena. Surely, there are lessons to be learned here for any nation seeking to improve its manufacturing position - or indeed, any other endeavour. One of the keys has to be an ability to think and see strategically and to recognise what is actually happening on the ground. Clearly, when it comes to the sub prime fiasco, there was either an unwillingness or, perhaps worse, an inabili-

IN BRIEF
Free 5-axis measurement seminars

Technology acquisitions for Wenzel
Global precision CMM company, Wenzel, has announced two new acquisitions Knotenpunkt GmbH and Volumetrik GmbH. Volumetrik is a X-ray computer tomography company and Knotenpunkt is a manufacturer of reverse engineering software, technology and CNC controllers - for more details, see feature on Wenzel on page 21 of this issue. www.wenzel-group.cmm

ty to think and see the reality. I would like to think that those who are familiar with quality assurance and quality control culture, such as readers of QMT, would have made a better job of it all after all, we have the culture, tools, technologies and techniques to envision, map, monitor, control and improve systems! Surely, some sort of quality audit would have produced plenty of corrective actions in the sub prime process? Or is it the case that the financial sector had plenty of quality systems, which complied with the appropriate standards but didn’t deal with the fundamentals i.e.an efficient system producing what the market apparently wanted, consistently, reliably, but which was poison for the world?

Brendan Coyne

CNES builds 3,000 tonne tension compression rig

New Bowers training and distribution facility
The Bowers Metrology Group has recently opened a new distribution and training facility in Shanghai, China. The 2,500 square metre facility will serve as the Chinese distribution hub for the company’s

Continued on page 5

Corus Northern Engineering Services (CNES) has manufactured a 3,000 tonne hydraulic test rig for Oil States Industries (UK) Ltd based in Aberdeen. The press is a complete tension compression test rig, which will be delivered to an Oil States customer in China, Tianjin Pipe Corporation (TPCO), who will use it to ensure its seamless steel pipe is fit-for-purpose. The press measures 13m(L) x

2m (H) x 2.5m (W) and weighs just over 70 tonnes. Oil States Industries is a global provider of deepwater production products and subsea pipelines for the offshore and onshore oil and gas industries. The test laboratories at Aberdeen are accredited to UKAS ISO 17025 and have their own in-house designed 2,000 tonne hydraulic press. www.corusnes.com

World leading metrology companies Renishaw, Metris, Mitutoyo and Wenzel, and CAD/CAM developer Delcam, are holding a series of free half-day UK seminars in Autumn 2008 covering Renishaw's Renscan5 five-axis measurement technology, including the award-winning REVO measuring head. Each of the events will cover the operation and applications for the new system, compatible software packages, its suitability as a retrofit option, but fundamentally the huge throughput benefits that the new technology can bring to users of co-ordinate measuring machines (CMMs). The first event will be held at Metris near Derby on 9th September, followed by an 11th September event at Wenzel in Gloucester and then at Mitutoyo's Andover offices on September 17th. During November there will be events at Renishaw's Wotton-under-Edge headquarters on Tuesday 4th, at Delcam's Birmingham headquarters on Tuesday 18th, and concluding with a northern event at Mitutoyo in Halifax on Thursday 20th November.
To register for the seminars, please use the on-line booking form at:

www.renishaw.info/roadshow, or contact Katie Hibbitt on 01453 524414.

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NEWS

bore gauging products that are manufactured in Bowers’ hi-tech manufacturing plant in Bradford, West Yorkshire. With exports currently accounting for 79% of company turnover, Bowers plan to expand the new facility further in the near future, with Bowers Shanghai acting as a distribution base for the company’s new range of Eseway Premium Rockwell Hardness Testers. www.bowers.co.uk

EVENTS
8-13 September 2008 IMTS08 International Manufacturing Technology Show Chicago, Illinois, USA www.imts.com 16-18 September 2008 NDT 2008 The 47th Annual Conference of The British Institute of NonDestructive Testing Shrigley Hall Hotel, near Macclesfield, Cheshire, UK www.bindt.org 24 - 25th September 2008 MEDTEC Ireland Conference Galway, Ireland www.medtecireland.com

The Measure of Success

Automated Precision and Metris joint distributor agreement
Automated Precision, Inc. and Metris have announced the formation of a joint distributor agreement. API will become a non-exclusive distributor for the Metris MCA Articulated Arm and the ModelMaker hand held scanner. At the same time Metris will become a non-exclusive distributor of the API’s Tracker3 Laser Tracker. www.metris.com www.apisensor.com

www.inspex.co.uk/ October 7 - 8th 2008 Northern Manufacturing exhibition Sheffield, UK www.industry.co.uk October 21 -22nd 2008 TCT exhibition & MM Live Exhibition Ricoh Arena, Coventry www.time-compression.com www.micromanu.com October 27 - 30, 2008 4th Annual European Lean, Six Sigma & Process Improvement Summit Hotel Okura, Amsterdam, The Netherlands www.europeanleansixsigma.com November 5-6th 2008 Manufacturing Technology exhibition Dublin, Ireland www.industry.co.uk November 18-20th 2008 AeroTest America Fort Worth, Texas, USA www.aerotestamerica.com 3 -6th December 2008 Euromold 2008 exhibition Exhibition Fair Ground, Frankfurt / Main, Germany www.euromold.com

Measure everything as easy as a cube.
FARO‘s portable 3D measurement systems make measuring complex objects easy. This includes alignment, calibration, inspection, reverse engineering, and as built documentation with a measuring range between 0 and 70m and accuracies up to 5 microns.

Hexagon German machine tool probe acquisition
Hexagon has acquired all outstanding shares in m&h Group. The Group consists of the three German companies m&h Inprocess Messtechnik GmbH, m&h Inprocess International Trading GmbH and m&h Inspect GmbH. m&h is a leading developer, manufacturer and distributor of machine tool probes including related software and services www.mh-inprocess.com

Hexagon to acquire the Chinese company
Hexagon has entered into an agreement to acquire Chinese company, Serein Metrology (Shenzhen) Co. Serein Metrology develops and produces a wide range of advanced precision measuring instruments in the micro area of the measurement technologies market. The company provides high quality products, QMT September 08

More information at www.faro-products.com or 00 800 3276 7253
FARO, THE MEASURE OF SUCCESS are aregistered trademarks and trademarks of FARO Technologies Inc. © 2008 FARO Europe GmbH & Co. KG. All Rights Reserved.

NEWS

solutions and services to the automotive industry, aerospace and defence industry, engineering industry, die and mould industry, electronics, IT and medical industry. Serein Metrology is based in Shenzhen, China, and today employs 98 people. The company had a turnover of approximately 4 MUSD in 2007 and is expected to grow at a double digit rate in the years to come www.serein.com.cn

Food testing lab for Beijing
Intertek, international provider of quality and safety services, has opened a new food testing laboratory in the southwest area of Beijing, China to offer an array of services to manufacturers, distributors, and retailers who produce, import, buy and sell food products in Beijing and Northern China. www.intertek.com

characterisation and design of micro and nano technology based products and systems. http://cemmnt.co.uk

CALL FOR PAPERS
Metromeet launches the call for papers for 2009
Metromeet, the 5th edition of the International Conference on Industrial Dimensional Metrology, will take place on 26 and 27 March 2009 at the Euskalduna Conference Centre in Bilbao, Spain. Metromeet has launched a call for papers to professionals and industry experts to share their experiences and knowledge. In the next Metromeet edition, organized by Innovalia Association, new solutions for metrological industry, robotics for metrology, optical measuring systems, calibration systems for the measurement of metal and the new hybrid system, amongst others, will be shown. The deadline for submitting papers ends on September 18th. www.metromeet.org

ECONOMIC INDICATORS

UK vehicle production rises in July
“Car output rose by 1% in July (to 131,079 units) and is positive for the year to date,” said Paul Everitt, SMMT chief executive. “The Qashqai+2, which was recently launched at the British International Motor Show, has gone into production and it is expected that the Sunderland plant will produce around 270,000 of both versions of Qashqai in 2008 and an estimated 450,000 vehicles will come off the line in total. Commercial vehicle production saw exceptional growth of 50% in July 2008 (at 20,997 units),” source: SMMT www.smmt.co.uk

US office for NanoSight
NanoSight, the nanoparticle characterization company, has opened offices in the USA at Morganville, New Jersey, to provide local sales, applications and service support to their growing family of users. NanoSight will share facilities with the complementary US nanotechnology company, XiGo Nanotools, a company applying NMR technology for nanoparticle characterization. www.nanosight.co.uk

European workshop maps metrology priorities
Following a roadmapping workshop held last May at Loughborough, and co-sponsored by CEMMNT (Centre of Excellence in Metrology and Nano Technologies), a report has been published highlighting the trends, challenges and opportunities facing measurement and characterisation. The workshop comprised of a diverse group of experts gathered from across Europe with interests in measurement and

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QMT September 08

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DIMENSIONAL METROLOGY

Blisks & integrated measurement

A complex new product development, Blisks, for the huge JSF programme, presents an unprecedented challenge for Rolls-Royce on how to integrate CMM measurement technologies into new manufacturing processes. By Brendan Coyne.

T

he Joint Strike Fighter, JSF, next generation tactical strike aircraft is a stealth, multi-role aircraft. Based on a single, common design with three variants, including a Short Take Off & Vertical Landing (STOVL) option, the end users will be the US Marine Corp, Navy and Airforce together with partner nations forces, such as the UK, and Canada. In 2001, the US Department of Defense selected the Lockheed Martin X-35 concept plane, which has now become the F-35 Lightning II Joint Strike Fighter. With an estimat-

ed programme requirement of 3,500 aircraft, the US government funded budget will be in the region of $298bn spread over 30 to 40 years. Aerospace manufacturer Rolls-Royce will con-

In the space of 11 years up to 2017, we will go from producing a Blisk every three months to one Blisk every eight hours.
tribute to the programme by manufacturing several key components, including highly complex Blisks. For conventional take off, there are two engine derivatives available. The F-135 engine is a purely Pratt & Whitney engine in which Rolls-Royce have no stake. The F-136 engine is a joint collaboration between General Electric and RollsRoyce, with Rolls-Royce responsible for the manufacture and supply of several key modules, one of which is the full fan system at the front end of

F-35 Lightning II

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QMT September 08

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DIMENSIONAL METROLOGY

F-35 engine test

the power plant. The fan system consists of three large diameter Blisks, which will initially be manufactured in existing Rolls-Royce plants in the UK. For those customers who wish to have STOVL capability, the Rolls-Royce Liftsystem is the only option. The Liftsystem comprises of four key components, one of which is the shaft driven liftfan. The liftfan contains a further two large diameter Blisks. The Liftsystem can produce a thrust of in excess of 40,000lbs. Compare this to the Harrier, which in combat mode in conventional flight only produces about 30,000 lbs of thrust. What does this mean in terms of a Blisk New Product Introduction (NPI) programme within the company? The first thing Rolls-Royce did was to

establish a Blisk pre-production facility, dedicated to manufacturing a range of new Blisks. Introducing many new manufacturing technologies, many of which had never before been applied on Blisks, the purpose of the pre-production facility is to finalise the manufacturing development and to seal the method of manufacture on each of the Blisk components and, then, to gradually increase the facility’s output to its full capacity. Dean Whiteside is responsible for measurement processes in Rolls-Royce’s UK Blisk manufacturing plants. Currently, Dean is probably the lead protagonist within the organisation for the need to develop 5 axis scanning technology within the measurement process for more complex geometry, such as aerofoils and free form shapes. One of the first challenges he faced was the establishment of the measurement cells at Hucknall, a Blisk pre-production facility, which had received a capital investment of approaching £1.3m in measurement systems alone. “At the start of the programme, we had to demonstrate our capability, in a small demonstration area, to produce one Blisk every three months. Now, we’ve migrated to pre-production and are required to demonstrate that we can produce at a rate of one Blisk per week. When we migrate from pre- production and go to full factory production, (in a facility yet to be built) the rate has to increase to one Blisk per 8-hour shift at peak vol-

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DIMENSIONAL METROLOGY

ume. So in the space of 11 years up to 2017, we will go from producing a Blisk every three months to one Blisk every eight hours. Clearly, we have a major challenge ahead of us in ramping up to these numbers.” This NPI programme is unprecedented within Rolls-Royce. Explains Dean Whiteside, “We are introducing up to six new products, whilst simultaneously introducing new manufacturing processes to produce these parts. We have very demanding customers in the Liftsystem and F-136 projects who are understandably pushing manufacturing to make sure they meet their critical milestones.”

ality which would allow us to produce a very large number of CMM part programs over a very short period of time for the six variants of Blisk.” Adding to the challenge was the absence of a physical part to program around on the CMM. “To meet the tight customer milestones, we had to minimise the time the parts spent on the CMMs. We couldn’t wait for the parts to arrive at the CMM and then begin writing the CMM program. This would add a significant lead-time onto the manufacture of the first off Blisks, which was completely unacceptable. When the actual part arrives at the CMM, I allowed a day per CMM program to test and prove out the off-line written part program on the actual part. For this to work, we required the off-line programming software to be capable of producing and simulating 90-95% of the required functionality with minimal time required for subsequent editing. However, we soon found that in reality the level of capability required fell some way short. For various reasons, the off-line programming systems were only capable of delivering 4050% of the required functionality. (These comments are not aimed at saying a particular CMM software does not deliver what we require. We’ve come to the conclusion within Rolls-Royce that there is no one single offline solution that provides all our requirements in terms of CMM programming capability).” The primary reason for this is that the Blisk component is one of the most complex parts that Rolls-Royce manufactures featuring a combination of prismatic and freeform geometry. The more complex functionality required to measure Blisks was not supported by the off-line systems. Also, several items of ancillary equipment that are key to the measurement process, such as rotary tables, were not integrated, at that point, within the virtual CMM environment. A true measurement process couldn’t be fully simulated prior to the part actually arriving at the CMM. This meant the measurement team still had to write a large proportion of the CMM programs on the physical part when it arrived at the CMM.

Measurement challenge
Blisk manufacture involves extremely complex processes. The majority of these processes are novel and, as a result, there has been a significant demand on the measurement processes to support and establish the capability of these processes. Measurement plays a critical role in this plant, not only in product conformance at the end of the line but also to assist in manufacturing development. “Right from the outset, it was clear to me that measurement, within a concurrent engineering environment, would play a key role in ensuring the successful delivery of JSF Blisks. To meet these tight schedules we had to utilise the capabilities of off-line programming of coordinate measuring machines (CMMs). For off-line programming, we required function-

Product Life Cycle Management
Adding to the challenge, the measurement process has to operate within the context of a Product Life Cycle Management (PLM) rollout being piloted by JSF Blisk manufacturing within Rolls-Royce. PLM works if all the data relationships are truly integrated. For example, in the Blisk programme, Design Engineering, based in Bristol are the authority for geometry of the product. They interface directly with the component owners, who themselves are the individuals responsible for the product within the manufacturing environment. The component owners can interface directly, (exchange geometry in terms of master models, stage models etc.) with the various machining process owners via UGS TeamCentre
QMT September 08

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DIMENSIONAL METROLOGY

within the manufacturing environment. The process owners are the individuals responsible for the various manufacturing processes used to manufacture Blisks. The ability to interface between Design Engineering, Component Owners and Process Owners provides full geometry associativity. If there are any design changes driven by Design Engineering an automatic cascade of these changes and the relevant associativity is applied to the manufacturing processes via the TeamCentre environment.

PLM does support concurrent engineering. But where does measurement fit in? “It doesn’t currently,” says Dean Whiteside. “ (As far as we are aware), there is no PLM solution that truly integrates the measurement process within the PLM environment as it does with CAM. The measurement process was isolated from the PLM/TeamCentre environment. It was and still is a stand alone process with no direct interfacing with the PLM system. This can cause major problems, particularly for the measurement process if geometry changes are not communicated to the whole integrated project team. Rolls-Royce uses UniGraphics Siemens PLM and we are in the very early stages of starting to understand how to migrate the measurement process into UGS PLM. But progress is slow and there is still a very long way to go! Today, measurement is an integral element of our manufacturing systems. We need to ensure that latest measurement capabilities are built into future PLM developments. Equally, we need to recognise that since original implementation, technologies have advanced. Alternative forms of sensor probing devices need to be investigated such as on-machine, and 5-axis CMM scanning, that potentially offer a more cost effective and integrated solution. These developments clearly need to be captured in the PLM environment.”G E-mail: dean.whiteside@rolls-royce.com

QMT September 08

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LASER RADAR MEASUREMENT

Laser radar in its sights
Janicki Industries utilizes laser radar measurement technology to develop innovative composite tooling for large-scale lightweight prototype aircraft parts
anicki Industries, based in Sedro-Woolley, Washington, USA, produces high-precision advanced composite tools and excels at designing and fabricating large complex composite tooling. The company’s (pole) models, test equipment and full-size metallic and composite

J

Metris Laser Radar

structures are typically used as prototypes for aerodynamic property testing, radar testing or for any other customer requirement. Today, tooling expertise developed at Janicki serves the majority of international aircraft OEMs as well as manufacturers of boats, motor homes, buses and monorails. The company has a growing involvement in tooling development for composite wind turbine blades, and occasionally participates in special projects, such as prototyping speedy racing yachts that compete in the renowned America’s Cup. When developing new tooling concepts for large prototype structures, Janicki faces short turnaround times and high-precision requirements. As a result, the company’s metrology specialists are fully occupied with systematic quality verification of structural assemblies being developed. “To meet the growing demand for tighter timing deadlines in developing large aircraft fuselage sections, our metrology team opted for three Metris Laser Radar systems to validate OEMs’ geometric requirements,” John Janicki, vice president of Janicki Industries, stated. “Deciding factors were that the laser radars operate without sphericallymounted retro-reflectors (SMRs) or remote devices, and reliably deal with composite surfaces and sharp scanning angles. In automatic mode,
QMT September 08

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LASER RADAR MEASUREMENT

Michael Batchelor, metrology manager at Janicki Industries. “Although Metris Laser Radar is hightech equipment, its use is quite straightforward. The laser radar unit is able to measure any surface point you can see within the measurement envelope of the system. The rugged industrial laser radar proved itself in our harsh composite milling environment as well as at remote outdoor locations.”

Giant fuselage section scanned
Nearly 6 meter in diameter and about 12 meters in length is the size of an all-composite fuselage section that has been developed for a new groundbreaking composite superliner aircraft. Janicki’s metrology engineers used Metris Laser Radars to accurately measure the detailed geometry of this immense fuselage section as well as an individual 60 degree section subassembly. As the Metris Laser Radar is able to gather data over extremely large areas in a contiguous coordinate system, the system can be positioned successively at multiple positions without requiring complicated reassembly of geometry point data clouds. This is achieved by scanning fixed tooling balls that allow the laser radar to determine its own new position relative to the fuselage section. Janicki engineers positioned the laser radar at 10 unique positions to cover all interior and exterior surfaces of the entire fuselage section. For the subsection assembly, 5 positions were sufficient. After gathering geometry data in uniform scans, they exported the digital model to third-party software for further numerical and graphical geometry assessment. In this case, they responded to OEM-defined requirements by delivering a point file along with a geometry verification report including point deviation data and information regarding critical features. The laser radar is a single operator measurement solution. Visible from behind the mobile workstation of the laser radar, the operator can point a clear large-dot laser to any desired point on the structure. This red dot clearly marks the approximate location of the invisible measuring beam of the laser radar. Based on imported fuselage CAD data, a Janicki metrology engineer specifies the scanning area by driving the red dot around the perimeter of the fuselage section. After defining the point density, the system scans the area in automatic mode. After acquiring the 3D coordinates of one point, the laser radar beam automatically redirects to the next point. The total time to complete a point pattern scan is in the order of minutes. The laser radar also supports manual point measurements, which can be recorded on command by steering the beam to the required surface location. Following this scanning approach, Janicki metrology engineers are able to accurately measure the large-scale fuselage surface, without requiring photogrammetry dots, SMRs, probes or
QMT September 08

Janicki Industries, Sedro-Woolley, Washington, UISA

we only need a single operator who defines and supervises scanning jobs. ” During operation, the Metris Laser Radar directs an infrared laser beam and processes the reflected light. Janicki purchased two Metris MV260 systems that cover a 60 meter radius, and one Metris MV224 with a 24 meter reach. On the basis of accurate (fibre) optics technology and beam angle specification, the laser radar is able to accurately determine the 3D coordinates of the surface point being inspected. The technical concept of the laser radar implies that measurement accuracy depends on the length of the laser beam: 0.016 mm at 1 m distance; 0.1 mm at 10 m and 0.24 mm at 24 m. Capturing only a very small fraction of the reflected laser beam is sufficient to make a valid measurement, thanks to the system’s innovative frequency modulation laser technology. As a result, the Metris Laser Radar, unlike laser trackers, can operate in any lighting conditions and on any surface with a reflectivity of one percent or more. Using Metris’ high-quality optical flat mirrors, the laser radar can additionally access surfaces that are otherwise unreachable. “Non-contact in combination with large scale is the most important asset of the laser radar solution,” said

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LASER RADAR MEASUREMENT

other remote devices. Compared to laser tracker equipment, where one person operates the tracker and the other one holds the device, the Metris Laser Radar system can be operated by a single person. This eliminates a second operator, who would otherwise need to physically access the many measurement locations on the concave surfaces of the fuselage structure. “Overall, when considering non-contact laser scanning in automatic mode, we succeeded in increasing geometry verification productivity by a factor of 5,” stated Michael Batchelor. “At the same time, the accuracy of the laser radar meets or exceeds our customers’ precision requirements. Besides high accuracy, the laser radar guarantees high measurement repeatability, which allows us to confidently perform direct pointto-point measurements.” Large-scale accuracy is a real challenge, especially since Janicki becomes increasingly involved in tooling projects for very large composite parts. Over the years, the company’s growing internal metrology group gained top metrology expertise and has innovate measurement equipment in house, including the three laser radar systems from Metris. The combination of specialized metrology expertise and market leading equipment speed up geometry verification to help meet tighter tooling project deadlines, and offers great opportunity to explore new business through metrology outsourcing projects. Originally, Janicki focused on developing CNC milling machines that convert CAD files into plugs, patterns, molds and prototypes parts for large items. As an innovation company that systematically searches for new emerging technologies, Janicki recognizes the potential of utilizing Metris Laser Radar as part of large gantry mounted drilling machines. In this case, the laser radar would provide independent adaptive positioning control of the drilling head, which in itself would drastically reduce the cost of the positioning overhead of these massive machines. The enabling metrology technology of the Metris Laser Radar would enable Janicki to design and build cost effective automated milling equipment to accommodate even larger composite parts to produce.G www.metris.com

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NIST

Focus on NIST
NIST "M Cubed" molecular measuring machine

The US National Institute of Standards and Technology (NIST) plays a significant role in underpinning US economic and technological development. By Thomas Shattuck

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he National Institute of Standard and Technology, NIST, is a non-regulatory agency under the United States Department of Commerce that aims to improve the standards of measurement to provide economic stability and technological development. NIST received approximately 755.9 million dollars this past year to fund its various projects and is currently seeking a 7.4 percent increase for the year 2009, though only a 1.4 percent increase has been approved by the US Congress. With the budget significant returns have been made. For every dollar spent on metrology, the Institute calculates a return of three dollars and thirty cents throughout industry as a whole. Within NIST, the Dimensional Metrology Program (DMP) aims to improve American competitiveness by providing metrological standards
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and tools for industries with a significant U.S. presence. DMP achieves their goals in many ways, most notably through coordinate-measuring machines (CMM) - particularly transportable sys-

For every dollar spent on metrology, the Institute calculates a return of three dollars and thirty cents throughout industry as a whole.
tems such as laser interferometers and laser trackers. The large scale metrology industry is rapidly moving to optical measurement systems. Unlike large fixed placement CMMs, these new systems can be easily transported to different measureQMT September 08

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Software for all...

...with CALYPSO
Let us show you how to get more from your CMM – or other Metrology instrument – whatever the make, with an upgrade to Calypso software from Zeiss. Interested? Contact us now to arrange a demonstration.

Carl Zeiss Ltd. Division of Metrology 2 Hadrians Way Glebe Farm Industrial Estate Rugby, Warwickshire, CV21 1ST Phone: 01788 821770 Fax: 01788 821755 Email: metrology-sales@zeiss.co.uk Website: www.zeiss.co.uk/metrology We make it visible

NIST

NIST CMM LAB ment sites, have significantly lower capital equip-

ment costs, and allow factory floor space to be rapidly reconfigured. New optical technologies that provide absolute distance measurement (ADM) capability eliminate (photos courtesy HDR the need to transport retroreflectors from the sysArchitecture, Inc./Steve Hall tem to the workpiece and the associated problems Copyright Hedrich Blessing) of beam breakage. For that reason, measurement technology using ADMs has exploded in recent years and numerous firms are developing new products and measurement services. The United States claims to lead the world in this technology, particularly in the development of ADM laser trackers. The DMP is supporting this crucial technology through development of a high accuracy 60 meter test range that can calibrate ADM ranging systems. Direct assessment of the errors in these (often highly proprietary) ADM systems helps manufacturers of this technology to improve the accuracy of their equipment and gives users confidence in the measurements. Using NIST’s existing tape calibration facility, augmented with a newly developed high accuracy long range interferometer system, represents a unique US national resource. Current test range calibration uncertainties are U(k = 2) = 2 µm + 3 × 10-7 L for cooperative targets (specially made to be ADM friendly) and U(k = 2) = 10 µm + 1 × 10-6 L for noncooperative targets . Along with improving metrological tools, the DMP is also interested in entrenching US technical standards in new fields. They have succeeded in several key areas including measurement uncertainty, traceability and standards for Cartesian CMMs. Furthermore, the DMP hopes to develop standards for laser scanning sensors increasingly used with various types of CMMs. This will allow for the accurate measurement of

objects in the <50 nanometre range. Examples of improvements in ultra precsion measurement include the creation of what is referred to as the "M Cubed", or the molecular measuring machine. It is currently located underground in a clean room at NIST's metrology wing to prevent environmental disturbances. Its primary use is ultra precise two-dimensional measurements and is able to draw lines on silicon as small as 10 nanometres wide and 4 nanometres high. In the Precision Engineering Division (PED), under the supervision of Doctor Michael Postek, several advances in metrological tools have been made. PED is split into multiple groups focusing on different aspects, all serving NIST's mission objectives. Like other divisions, the PED serves as both a research organization and as a calibration service. The division has made great strides on the smaller scales including the creation of a 150 x 150 millimetre reference artifact with less than 30 nanometre measurement uncertainty and has completed experiments for next generation of single crystal critical dimension reference material. This allows for the accurate comparison of size and provides a point of reference for measurements on a nanoscale. Other recent PED accomplishments include blind tip estimation for critical dimension atomic force microscopes. Blind estimation is particularly useful because the detailed shape of the tip characterizer need not be known. Until very recently, blind reconstruction could only be applied to conventional non-reentrant tips. The surface of such a conventional tip can be represented by a single-valued function. Blind reconstruction has now been extended to objects with multi-valued heights by using a dexel-representation for such objects. As for the future of metrology and the growth of manufacturing in the U.S. and internationally, Dr. Postek believes that NIST will play a central role. " NIST’s specific role as a neutral third party with technical excellence provides NIST a unique role for national and international standards. Well written standards have positive externalities to industry. These externalities include the avoidance of costs for individual (i.e. idiosyncratic) testing, optimizing capital purchases (by allowing meaningful comparisons between different products) and the lowering of barriers to new technology adoption through increased confidence and technical information.” Dr Postek says that early adoption allows economies of scale to take place, letting mass production create affordable, reliable tools sooner. Also, with the ability to compare similar products, optimal decisions can be made, promoting intelligent investments of capital and sustained growth. G www.nist.gov E-mail: thomas.w.shattuck@Vanderbilt.Edu
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COMPANY PROFILE

Wenzel - the first 40 years

XO87 40th Anniversary Edition bridge type coordinate measuring machine from Wenzel UK

40 Years of Wenzel Precision are being celebrated this year. Strategic acquisitions look set to play a major role in the company’s drive for dynamic growth. By Brendan Coyne

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t’s 40 years since 1968 Werner Wenzel established Wenzel Präzision in Wiestal, Germany, Since then, the company has developed into a major force in the world of coordinate measuring machines with over 5,500 CMMs manufactured and sold worldwide. Now headed up by Werner Wenzel’s son and daughter as joint managing directors, Frank Wenzel and Dr. Heike WenzelDafler, the company is rapidly moving to become even more of a major player with a series of strategic acquisitions and investments, from the

USA to Singapore India and China, together with on-going technical innovation. During these forty years, the key characteristic of the family-owned company has always been the same - one of family values, particularly with respect to care of its employees. This is something both Heike and Frank Wenzel are determined to preserve as the company grows. This dynamic growth is taking place in a world where there are probably too many CMM manufacturers. Market consolidation will inevitably take place over the coming decade. Heike and Frank Wenzel are adamant their strategy will ensure that Wenzel will be among the top four of five CMM manufacturers in the world, alongside Mitutoyo, Zeiss and Hexagon Metrology. Typical of Wenzel’s strategy of purchasing key technology is the recent acquisition of Knotenpunkt GmbH, Balingen, world leading manufacturer of reverse engineering software, technology and CNC controllers. "By the strategic acquisition of this reverse engineering technology provider Knotenpunkt, Wenzel extends it's leading position as a provider of design systems for the recording and processing of surfaces," says Frank Wenzel. The product

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COMPANY PROFILE

range of Knotenpunkt covers the whole area of digitization and processing of point clouds and the complex field of reverse engineering. Its software includes PointMaster for reverse engineering and measurement. Integrating PointMaster into Wenzel’s DesCAD design software provides all the functions - from digitization of a model to milling - with just one tool. Supporting this area is Shapetracer, which records surfaces and contours of physical parts. On the software development side, Wenzel has announced Metrosoft QUARTIS, the first measuring software based on the innovative Microsoft Office Fluent user interface. The new interface is very clearly arranged, flexible and goal-oriented. The result is a highly innovative operation concept, which enables all users easy and fast access. Deliveries of QUARTIS will start in January 2009, say Wenzel. Yet another strategic technology acquisition is computer tomography company, Volumetrik GmbH. Announced in July, this acquisition takes Wenzel into a fast developing x-ray CT technology with strong growth potential. Using computer tomography machines it's possible to make contactless 3D-measurements of inner and outer structures in a range of materials and in many diverse applications. "By integrating our many years of experience and competence in the field of computer tomog-

raphy into the WENZEL Group we have the best opportunity to compete in the market for contactless volume measurement with our innovative technology", says Dr. Martin Simon, managing director of Volumetrik.

UK celebration CMM
To celebrate Wenzel’s 40 years, Wenzel UK has announced the XO87 40th Anniversary Edition bridge type coordinate measuring machine. Coming in at a remarkably competitive price of £34,040 +VAT, the package includes a full CNC system, all granite axes design with a measuring stroke of X-800, Z-700 & Y-1000mm. Volumetric uncertainty is 2.5+L/300µm. The package includes a Renishaw PH10/TP200 Probe System, Metrosoft measurement software, new Fujitsu PC with Flat screen & printer plus delivery Installation & 12 months warranty together with full training for 4 people. Lastly, Wenzel UK are throwing in a free Renishaw SCR200 Toolchanger. Andy Woodward, managing director of Wenzel UK comments, “This special edition of the XO CMM will enable our UK customers to take advantage of a medium sized CMM at a very special anniversary price, coupled with what many customers in this market segment require, immediate delivery.” G www.wenzel-cmm.co.uk

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PRODUCTS CMMs

Revolutionary prototype tooling method
To quickly and cost-efficiently bring new products to the market, the automotive and other industries require rapid ways of building stable and accurate prototype tooling. A novel approach from Metronor and Tetrafix sets new standards in terms of tool alignment speed and accuracy, combined with mechanical stability, while using only a few standard components to create a wide variety of geometries. The required tool geometry can be built in minutes using a patented concept with structures made up of modular carbon fibre tubes and adjustable joints. The Tetrafix structure permits free movement of the detail adapter in space, making the positioning process quick and efficient, and the structure is simply locked in place using a hex key once the correct position is achieved. Thereafter, the LED cluster is removed and the tooling detail is clamped in its place. Once locked, the entire structure is extremely stable and fully able to withstand the shop floor. To align tooling details like clamping devices, net blocks

and indexing pins to within 0.1 mm accuracy, a special tetrahedron cluster with a number of Light Emitting Diodes (LEDs) are clamped onto the tool detail adapter. These LEDs are monitored by a Metronor DUO portable coordinate measurement system, providing continuous feedback on position until the detail is in the required position. www.metronor.com

Tube measurement solution
FARO, provider of portable 3D measurement devices and TeZet, the Swiss-based tube measurement software specialist, have entered into a new European technology and marketing agreement for tube measurement. Under the agreement, TeZet’s tube specialised software solution TeZetCAD, will be integrated into portable devices for 3D measurement - the FARO ScanArm and FaroArm. The innovative element of the agreement is the ability to measure freeform bent tubes with the FARO Laser ScanArm so that tube benders can actually bend tubes by extracting them graphically from CAD

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CMMs

drawings.TeZet offers a software module for FARO ScanArms that allows automatic calculation of tube data during the scanning procedure. The user no longer needs to use the complex and lengthy method of converting millions of points in order to extract the tube coordinate and bending data necessary for masterpiece inspection and comparison within the production procedure. www.faro.com

The Zenith of CMM technology?

Front cover story Metris LC60D laser scanner revolutionizes digital inspection
The Metris LC60D next-generation digital 3D line scanner more than triples today’s common scan rates. LC60D strengthens and accelerates the digital inspection process by making the digitizing process faster and more straightforward.

of the LC60D scanner are equally beneficial for quality control and reverse engineering applications. To effectively scan surfaces with varying colour or reflectivity, Metris has introduced third-generation Enhanced Sensor Performance (ESP3). ESP3 functionality not just provides automatic real-time adjustment of sensor settings between successive laser stripes, but dynamically adapts laser source intensity

Measurement versatility
Latest addition to the Tesa vision system range is the Visio 500. Employing a moving bridge mounted on airbearings, the Tesa Visio 500 is a high speed, high accuracy multi sensor system Measuring table (X,Y) is 400 x 500mm with a Z axis up to 300mm. Visio 500 can be equipped with a CCD camera, a TesaStar probe head or a touch-trigger probe coupled with a PC video camera. Able to meet challenging measurement features on a component, the Teas Visio 500 Universal version can be fitted with any optional components, such as black and white CCD camera, red or white light or TTL laser scanning sensors. Different systems for clamping measured components can be mounted on each model, including a fourth axis rotary device for measuring cylindrical parts. Measurement software is PC-DMIS. www.tesabs.ch

Aberlink claim the industry’s best performance to cost ratio for its new Zenith Too range of large capacity CMMs. The new series of CMM ] consists of 10 machines with XYZ capacities ranging from 1000x1000x600 to 1000x3000x800mm. The Zenith Too range is an all aluminium construction with advanced drive design and raised guide-ways .This ensures extremely low inertia characteristics for high speed operation. In addition, its measuring structure is completely independent of the machine’s granite surface table. The Zenith Too’s low thermal mass and robust characteristics enable accurate measurement of large components both on the shopfloor and in a QC controlled environment. www.aberlink.co.uk

A major leap forward compared to its LC50 predecessor, the LC60D line scanner delivers a significant increase in productivity, which is achieved by speeding up the image acquisition frame rate from 25 to 75 Hertz. In combination with 15% wider laser stripe and 17% higher point resolution, the scan speed of the LC60D reaches 75,000 non-interpolated points per second The massive amount of measurement points acquired at 15 micron accuracy radically increases the surface area the scanner is able to capture and process. As a result, LC60D operators can complete scanning jobs up to 3 times faster. This allows manufacturers to drastically compress the inspection cycle time for freeform parts, or boost the number of features that can be scanned in the same time frame. The digitizing capabilities

and camera sensitivity for each individual point of the laser stripe. This is achieved through rolling shutter imaging technology that ensures maximum data coverage on all surface materials and shapes, irrespective of surface finishing and lighting conditions. In case of very shiny surfaces, a new reflection filter removes fictive scattered points resulting in clean scan data. ESP3 even allows glossy convex surfaces to be captured in a single movement. ESP3 offers customized laser intensity for each individual laser stripe point. With this capability, LC60D ensures maximum data coverage for sheet metal, turbine blade, plastic and machined metal part, wheel rim and many other applications in all lighting conditions. www.metris.com

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QMT September 08

PRODUCTS SURFACE & FORM

For metrology only a ruler is simpler to use...

Form and surface measurement systems confirm honing’s stock removal credentials
The introduction in the 1970s of superabrasives such as cubic boron nitride (CBN) transformed honing from what Gren Lewis, managing director of Sunnen Products, describes as a cleaning-up process to a stock removal process capable of removing metal faster and more accurately than grinding. It is also acknowledged to be a cost-effective alternative to other processes such as hard turning, reaming and roller burnishing. “Today it is possible to hone virtually any material, apart from lead and wood, with the aerospace industry, for example, looking for better than half-a-micron accuracy,” he says. In fact, the latest generation CNC honing systems can produce hole size accuracies of 0.25 micron, with minimal variation and no operator intervention. In responding to customers’ demands for ever-tighter dimensional accuracies, Gren Lewis is adamant that “it is essential to be able to measure what it is you are seeking to achieve”. This is why the gauge room adjacent to the machining area in Sunnen’s 1200 sq. m. premises in Hemel Hempstead, Hertfordshire, is equipped with a Mahr MarForm MMQ44 QMT September 08

Formtester and a Mahr MarSurf S2 surface measuring system. The MarForm MMQ44’s high-precision X, C and Z measuring axes make it possible to perform any form measuring function; monitoring deviations in geometry or position for parameters such as roundness, cylindricity, straightness and parallelism. Various modules can be used to configure the system to an end-user’s exact requirements, whether in semi-automatic measuring mode with, for example, a manual centring and tilting table, or in fullyautomatic measuring mode. The MMQ44 used by Sunnen is fitted with a manual T2W inductive probe, with the probe arm capable of swivelling though 180° and a variety of clamping possibilities allowing access to difficult-to-reach surfaces, In addition, easily exchangeable probe arms accept a wide range of styli for wide measuring versatility. The MarSurf S2, which incorporates a dedicated processor, uses the tactile stylus method of roughness and waviness measurement that allows a two-dimensional profile to be calculated and documented to international standards. It is a semi-portable device for roughness and waviness measurement and evaluation in which the measuring conditions are quickly set and saved as a measuring program. Pressing two keys www.qmtmag.com

...but nothing is more powerful than a NEXIV
iNEXIV VMA-2520 Metrology – the science of traceable measurement. In the production environment, the need for speed and convenience often conflicts with requirement for accuracey, repeatability and cost – until now. With the launch of the new iNEXIV VMA-2520, you can gain the convenience of a ruler with the accuracy and precision that comes from autofocus-based video measurement. Just pick, load, measure and respond. • Compact and simple to use
• Combines a 250 x 200mm stage • Large working distance • Ideal for rapid QC checks and demanding R&D work • Laser autofocus option for faster measurement speeds • Touch-probe compatible for greater versatility Ask for a demo now, and run the rule over how the new bench top iNEXIV VMA-2520 measures up to your QC challenges.

www.nikoninstruments.eu/inexiv

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MICRO & NANOMETROLOGY
plus START on the keyboard equates to ‘measurement finished, documented and saved’, and an integrated high-resolution thermal printer provides Sunnen with an immediate log of results, profiles, curves and lists, as well as date/time and workpiece/company texts. “Sunnen carries out extensive honing trials in its Technical Centre prior to any machine purchase because our customers do like to see that components can be honed to their specification. The best way to check the roundness and concentricity of any honed component is on a computer-based form tester and the same applies to checking surface finish, so this very accurate inspection equipment is essential because, for our customers, seeing really is believing.” www.mahr.com Carl Zeiss SMT, a leading global provider of electronand ion-beam imaging and analysis equipment, has introduced a new, improved Helium Ion Microscope called the ORION PLUS. The original ORION instrument, introduced a year ago, demonstrated that Helium ion microscopy has a uniquely powerful set of features that allow scientists to see things never before visible. The ORION PLUS incorporates several design enhancements that deliver improved imaging: The tip geometry has been modified to increase the accelerating voltage of the helium ions, resulting in improved resolution; A new “Clear View” sample cleaning system combines plasma cleaning, heating elements and an in-situ vapour cleaning technique to remove hydrocarbons from the sample and the environment preventing re-deposition in the area being scanned, which results in increased surface detail; An enhanced signal collection technique called “Signal Boost” increases electron collection at short working dis-

Advanced 3D and 4D surface texture analysis
Olympus and Digital Surf have announced an agreement whereby Olympus will supply users of its LEXT OLS3100 confocal laser scanning microscope (cLSM) with 3D surface texture and micro-geometry analysis software based upon Digital Surf’s Mountains technology A Mountains analysis document is built frame by frame in an intuitive desktop publishing environment with a multi-language user interface. Realtime 3D imaging and intelligent pre-processing to maximise image quality make it easy to locate and visualise

surface features and anomalies at any zoom level or angle. Surface roughness analysis is carried out in accordance with advanced filtering techniques as defined in the ISO 16610 standard, including the new robust filters used by the automotive industry. A full set of 3D surface parameters are generated in accordance with the new ISO 25178 standard, the first international standard on 3D surface texture, which provides a solid foundation for industry’s transition from 2D to 3D surface analysis. Dimensional checking includes step heights between two different zones of interest on the surface, for example on MEMS and mechanical components used in the electronics and other industries. Moreover, a sub-surface layer can be extracted from a surface for independent analysis, e.g. the flatness of an extracted layer can be calculated with a single click. Numerous other analytical studies include: functional parameters used by the automotive industry, grains and particle analysis for applications in metallurgy and nanotechnology, as well as advanced statistical options. In addition to the analysis of

3D surfaces and 2D profiles that are extracted from them, Mountains provides new functions for analysing the evolution of 3D surfaces with respect to time or other 4th physical dimension parameters such as temperature, pressure or magnetic field. In addition, simulated flights over 3D surfaces changing in time can be output to video for animated presentations. E-mail: microscopy@olympuseuropa.com www.microscopy.olympus.eu

Improved Helium Ion microscope sets new standards for imaging resolution & brightness

See it. Measure it.
Vision Engineering’s pioneering range of patented optical and video non-contact measuring sytems provide microscoperesolution views of the component features you want to measure.

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

Low contrast? Black-on-black? White-on-white?
No problem... Your measurements will be accurate. Systems range from simple 2-axis 'shop floor' optical and/or video measuring microscopes to 3-axis Video Edge Detection measuring platforms.

50 years of Excellence in Ergonomic Microscopy
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MICRO & NANOMETROLOGY

tances for improved signal to noise; and An operating mode called “Quiet Mode Imaging” is an approach based on the use of a cryomechanical pump for cooling the source – instead of liquid nitrogen – where users can virtually eliminate vibration for noise-free images. This approach also provides a colder ion source, which yields an increase in brightness. Dirk Stenkamp, a member of the Board of Carl Zeiss SMT, said, “We are proud of the magnitude of improvement we have been able to achieve in only a year of development since the introduction of the first commercially practical Helium ion beam microscope. We will continue to push the envelope of advanced microscopy, delivering solutions that enable scientists to see and create at the nanometre scale.” www.smt.zeiss.com

Increased range of variable pressure FESEM
Hitachi High-Technologies’ new SU6600 variable pressure field emission SEM further increases its range of high performance electron microscopes. Key to the performance of the SU6600 is the combination of the advanced new electron gun and novel vacuum control system. The newly developed

Schottky field emission electron gun can deliver in excess of 200 nA probe current to give outstanding analytical results with excellent stability and sensitivity. The analytical chamber allows the simultaneous accommodation of EDX, WDX and EBSD (electron backscatter diffraction) systems with optimum geometry for comprehensive materials characterization. The SU6600 also features

an Automated Differential Aperture (ADAPT) system, which automatically inserts a differential pumping aperture for variable pressure operation – maintaining maximum flexibility in high vacuum mode and ensuring there is no manual intervention required when switching to low vacuum mode. ADAPT operates with a simple mouse click and the system is designed to ensure that there is no field of view restriction even when the aperture is in place – to aide low magnification navigation and imaging. Imaging and measurement capabilities include Hitachi’s high-sensitivity, TV-rate 5-segment BSE detector, environmental secondary electron detector (ESED) and an automated 3-D measurement system. The 3-D measurement software enables fast 3-D visualization of the specimen along with industry standard height, area and surface roughness measurement. www.hitachi-hitec-uk.com

OPTICAL MEASUREMENT AND INSPECTION
Measurement of steep flanks and complex geometries True color information registered to 3D data Traceable results even on highly sculptured surfaces Usable on highly reflective and inhomogeneous surfaces Highest resolution across measurement areas of several mm Comprehensive roughness measurement capabilities, conforming to the latest ISO standards Usable in the lab and as Inline measurement sensor
Alicona UK Alicona UK Ltd. Lime Tree House 15 Lime Tree Walk, Sevenoaks Kent TN13 1YH UK phone: +44(0)1732 746670 fax: +44(0)1732 465500 e-mail: sales.uk@alicona.com

+ + R a d i i a n d a n g l e m e a s u r e m e n t + + M e a s u r e m e n t o f p o l i s h e d e d g e s + + Va r i a n c e a n a l y s i s + +
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QUALITY MANAGEMENT SYSTEMS

Global approach to QMS
World leading industrial fasteners company, Anixter Fasteners, has standardised its global quality management system on a single platform solution.

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nixter Fasteners, the world’s leading supplier of industrial fasteners and C-class components to a wide range of industries, has implemented a tailored enterprisewide business management system as a unified, single platform solution for quality management. Operating over 60 sites worldwide and part of the $6 billion Anixter Inc organisation, quality management is a keystone to Anixter Fasteners’ global business success.

Although an essential element for Anixter Fasteners, quality management has not always been an easy process to manage. This is not unexpected for an organisation of this scale that has 60+ sites, many of which include acquired businesses and all with their own particular quality management systems (QMS) and operating platforms. Such was the situation facing Adrian Lloyd when he took on the role of Global Quality Systems Manager. Finding a solution to address the integration of all the different QMSs – and the mind-boggling number of records and documents they contained – into a single, scalable and flexible system would be a mammoth task. To attain his goal Adrian Lloyd would require the cooperation of all the various offices and personnel. In addition, he would need the full support of a meticulous IS department that would quarantine and test any new solution he proposed to run on the organisation’s extensive network. “My role was, and remains, to bring all our quality management into one place so that we could develop a single company-wide repository and resource for quality information. We looked at several different systems applicable to our size of business and we settled on Proquis Enterprise
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QUALITY MANAGEMENT SYSTEMS

with the allCLEAR process mapping tool as the solution to producing a cohesive QMS,” says Adrian Lloyd.

Phased implementation
Anixter Fasteners purchased Proquis Enterprise with allCLEAR process mapping in January 2007. Proquis supplied a range of tailored modules that would underpin the fastener company’s quality management approach and its ISO 9001 (Quality), ISO 14001 (Environmental) and ISO 18001 (Occupational Health & Safety) accreditations. In total the company bought 8 modules: · Audit Management · Customer Care · Document Control · Equipment Control · Health & Safety · Issues & Actions · Personnel Management · Supplier Control The software was tested for 6 months by the Anixter IS department, with further testing by the quality management department prior to final configuration. The system went live in January 2008. “We are now using and benefiting from the majority of the Proquis modules, including Audit Management, Document Control, Customer Care, Supplier Control, Issues & Actions – which links across all the modules and, to some extent, Personnel Management,” says Adrian Lloyd.

mountains of spreadsheets and manual records have been levelled. “We now have an automated approvals process with all documents held in a single repository. This saves a lot of time in finding the right document, making changes and gaining approval for those changes. We simply don’t need to keep manual records anymore as we can view all superseded documents within the system,” says Adrian Lloyd. “This is a fantastic development for us as it means that instead of trying to manage and use 9 different paper based quality systems, the team members are able to use their time to develop standardised schemes that we can roll out across the entire company.”

Supplier management
With the massive range of products that Anixter Fasteners provides, supplier management is paramount to quality management. “We had 6 different systems populated with supplier data. This took repetition to the extreme. With Proquis Supplier Control, we have reined this in and have taken a lot of time to clean up the data. Now we have 4997 clean records on Proquis. The flexibility of the system has allowed us to configure this module to support our supply chain development programme and we are currently populating the system with further supplier data such as credentials, capabilities, and certification. It will give us a complete view of everyone we work with throughout the world,” he says. A major boost to efficiency and productivity has been delivered by the allCLEAR process mapping tool. This enables process maps to be formed using text alone, using punctuation to determine the box type. This is far quicker and more efficient than drawing the boxes as required by other softwares. allCLEAR also provides the facility to multi-layer processes and link one to another, allowing management systems to be truly integrated. Proquis has also allowed the quality team to assign ownership to particular documents, which has provided additional time savings by streamlining the way documents can be worked on and updated. “Proquis provides us with the ability to engage other departments by allowing them to update documentation themselves. They no longer need to send everything back to Quality Management for amending. The system allows full traceability and so all changes to documentation can be tracked to the originator of each and every amendment,” says Adrian Lloyd. Six months of use has provided Anixter Fasteners with benefits that will maintain its drive on quality management and strengthened its competitive edge. Once the remaining modules have been implemented the system will be tempered further and will deliver more operational benefits. G www.proquis.com

Audit dividend
The Audit module is fully implemented for internal auditing. This is paying dividends in allowing the quality management team to take control of site audits. “We can schedule audits from a central point and easily assign auditors to sites. Via Proquis, we are able to see exactly what is going on for each audit. Moreover, we have been able to standardise on the audit procedure across the Group and establish common questionnaires and common scoring methods, completely replacing idiosyncratic practices prior to Proquis QMS,” says Adrian Lloyd. “The system has helped us to establish and implement escalation rules for closing out issues. If these are not followed and the issues remedied, then managers are alerted of the outstanding work. In all this has given us access to a highly visible workflow that we never had before,” he adds.

Documentation controlled
A business on the scale of Anixter Fasteners generates massive amounts of documentation but with the Proquis Document Control module
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SIX SIGMA & LEAN

Photo (from left) David Scrimshire (TEC), Mike Burrows (Burcas) mark Wingfield (A&M EDM), Paul Randle (Tamworth Heat Treatment) and Bob reeve (MAS -WM)

Lift off for Burcas
A supply chain development programme based on a six sigma and Lean approach leads to a £1m aerospace contract for Burcas

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he power of a world class supply chain is helping a West Bromwich manufacturer secure over £1m of new orders from the aerospace industry. Burcas, which celebrated its 65th birthday last year, has embarked on the Manufacturing Advisory Service – West Midlands’ (MAS-WM) ‘Lift Off’ programme to improve performance and introduce new processes across eleven of its closest suppliers, including A&M EDM, Bohler, Carbide Dies Birmingham and Tamworth Heat Treatment. The closer working relationships have had an immediate effect on efficiency and communication, not to mention playing a crucial role in contracts for Hentons, Hampson Aerospace and Sumitomo Precision Products – the latter focusing on the production of landing gear parts for the Airbus A330. Black Country based Burcas has a turnover of over £6m and employs around 80 people. Its work with the aerospace industry has increased since the loss of key automotive contracts in the region over the past few years, although the company has not lost touch with its roots and still produces a number of traditional products, including precision tools and paper-cutting knives. On the shift to a niche industry, Mike Burrows,
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managing director, is delighted at the progress to date: “The nature of our business means that we are continually looking to target new markets and this was one of the key considerations behind our logic for taking part in the Supply Chain Development Programme.” He continued: “Aerospace suited our ability to produce precision parts and we quickly identified a need to embrace six sigma and lean enterprise practices, in order for us to gain accreditations and be able to conform to the strict quality standards expected. “We got talking to Bob Reeve at MAS-WM and he introduced us to the ‘Lift-Off’ project, which would provide funding towards the creation of a working group of suppliers that could learn from each other and an external consultant to become more competitive. It was an easy decision to make.” Industry leaders, TEC Transnational, were brought in to deliver the programme and identify key goals for each individual company and how this impacted on Burcas’ performance. A series of AS9100 approved six sigma training courses were delivered, whilst a tailored programme of activities improved supplier performance and encouraged a ‘change agent’ culture
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Minitab Drives Quality Improvement.

The World Trusts Minitab for Quality
3M Avery Dennison Black & Decker Boeing Eastman Kodak ExxonMobil Ford Motor Company General Electric Hewlett-Packard Monsanto Multibras Eletrodomesticos SA Samsung Aerospace Toshiba Whirlpool
Plus the leading Six Sigma consultants and more than 4,000 colleges and universities worldwide.

The best way to deliver better products and services is to use Minitab® Statistical Software to analyse and improve your processes. Quality professionals worldwide use Minitab because it:
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SIX SIGMA & LEAN

whereby representatives from each firm would absorb best practice and pass it onto their colleagues. Mike, who is the third generation of Burrows to own the business, continued: “At the same time this was going on, we made a firm commitment to SBAC’s SC21 initiative, a specified set of criteria for supply chains in the aerospace industry. The standard, designed to ensure competitiveness, requires conformance in three areas; accreditation, development and performance and rela-

tionships both from a customer and supplier perspective. In short, the ‘Lift Off’ programme gave us the impetus we needed to make this happen.” Burcas' investment in the latest manufacturing technology and its supply base has seen the company boost its presence in the aerospace sector, with this particular industry making up 25% of its growing £6m turnover. Following the deal to supply landing gear components for use in the new Airbus, the firm has also been recognised as an approved supplier to Messier Dowty, a move that could significantly increase its presence in the global marketplace. Bob Reeve, MAS-WM Adviser, added his support: “The project has provided Burcas with a host of operational performance benefits, with possibly the most striking being a 100% success rate in quality, cost, delivery and research to the end customer.” Importantly, the supply chain development programme has also allowed other suppliers to refocus their activities towards the buoyant aerospace arena. For example A&M EDM and Carbide Dies have all received industry training and this has led to accreditation to the AS9100 quality standard. G MAS contacts: Jessica Hope - MAS National Network – E-mail: jessica.hope@gyrointernational.com Tel: 0161 876 5522

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PRODUCTS SPC & DATA COLLECTION

Flexible connectivity tool
Zontec Inc. has released Synergy 2000(TM) Multi-function Toolbox, a data integration program that interfaces its statistical process control (SPC) software with a variety of multi-vendor hardware platforms and manufacturing systems. Using the Toolbox, Synergy 2000 users can achieve compatibility with previously isolated systems, enabling them to easily perform SPC charting, analysis, traceability and reporting on any data regardless of its origin. It is a complete plug-and-play module that requires no additional programming or software customization of the Toolbox code. The Multi-function Toolbox is designed for: * Real-time data collection from CMMs, PLCs and other process control devices * Integrating data from ERP , LIMS, SCADA and other manufacturing systems * Migrating legacy data

plant floor to the Data Center. www.zontec

Measurement software includes analog gauging & QDAS certification
A new version of GageMetrics, the precision measurement software from ASI DataMyte, includes the ability to communicate with analog gauging, including LVDT probes. GageMetrics Version 2.0 now works seamlessly with the ASI DataMyte Model 916 Precision Gaging Multiplexer to interface with standard LVDT analog probes and highfrequency miniature IET probes. The new version also supports Marposs DigiCrown digital probes in addition to Solartron Orbit probes. With the release of Version 2.0, GageMetrics Software is also Q-DAS certified. The QDAS ASCII data transfer format alow comparison of data from a variety of measurement systems without complications, allowing for consistent data management and analysis. In

from other SPC programs, business applications and databases * Creating multiple Synergy 2000 Data Table instances at one time * Bridging OPC servers and the Synergy 2000 OPC client * AIAG (Automotive Industry Action Group) Quality Measurement Data (QMD) support for standard gauging devices The Synergy 2000 Multifunction Toolbox was developed within the Microsoft .NET(TM) programming environment for applications that connect seamlessly from the

addition to the Q-DAS File Exchange format, GageMetrics also exports data in other formats: - ASI DataMyte GAM Files used by ASI DataMyte Importer to insert data into the database - Text files used for ASI DataMyte DataMetrics software and Microsoft Excel to perform in-depth analysis Before the availability of GageMetrics, many precision measurement applications required a steep learning curve and many trial and error sessions before they could be implemented on the shop floor. GageMetrics uses clear and simple colour-coded graphics that minimize training time, startup time and the potential for operator error. These features also minimize differences from one user to the next, ensuring reproducible results across different operators and shifts. Data from both types of applications is stored in the same networkable database for analysis and correlation studies. www.asidatamyte.com

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X-RAY INSPECTION

Food inspection gets better
New inspection X-ray technology developed by European researchers is helping to ensure that the only thing in people’s dinners is the food itself.

F

inding a snail in a salad, a fish bone in a supposedly boneless fillet or opening a soup packet to reveal mouldy contents is an unpleasant – and potentially unsafe – experience. Small foreign bodies and packaging defects are frequently not detected by food producers, but a new X-ray inspection technology developed by European researchers is ensuring that the only thing in people’s dinners is the food itself. For consumers, a more effective method of inspecting food products before they reach supermarket shelves means better-preserved and cleaner food on their dinner tables – and a reduction in the risk of food poisoning. An improved inspection system also means producers can offer better quality produce, reduce the risk of spoilage, and gain a competitive edge over rivals. Already in use commercially, the technology developed by the Modulinspex project uses lowenergy X-rays to produce highly detailed images of food products and packaged goods. The images

are then scanned via inspection software that can automatically detect any irregularities accurately and quickly. The system can be used to check seals on food wrappers, locate packaging defects and find foreign particles of any size in any kind of food, from maggots in apples to grains of sand in bread. Even in an era of high food standards and sterilised packaged produce, those problematic foreign bodies and packaging flaws are more common than most people realise, says Jørgen Rheinlænder, the managing director of Denmarkbased InnospeXion, which helped develop the technology. Rheinlænder was the project coordinator for Modulinspex. “Go down to your supermarket and pick up a package of dried pasta,” he says. “About one in ten will have pieces of pasta trapped in the seal that can let air and moisture in and spoil the product.” Rheinlænder notes, for example, that some bacteria may spread on poorly sealed produce and go unnoticed by consumers until they end up spending the

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X-RAY INSPECTION

Participants in Modulineex are: Oy Ajat Ltd., Finland Cavendish Instruments Ltd., UK Zenon S.A. Robotics and Informatics, Greece Detectronic A/S, Denmark Institute of Electronics and Computer Science, University of Latvia

next day on the toilet or at the hospital.

Lower energy, higher definition
Until now X-ray inspection technology used by food processors was dominated by high-energy intensity systems not unlike those used to scan luggage at airports. These are able to detect a pebble in a package of corn but lack the resolution to pick out a grain of sand in a bag of flour. The higher-resolution alternative, low-energy Xrays, had not been used because it took too long to scan the produce and would slow the rapid pace of production in modern processing and packaging plants. The European researchers working in the EUfunded Modulinspex project have brought both greater speed and accuracy to the table. By attaching a CMOS chip to the crystal that detects the X-rays in a low-energy system they have been able to build a detector capable of taking 300 images per second, enough to capture a crisp image of products moving on a conveyor belt at half-a-metre per second. The X-ray images have a resolution of 0.1 millimetres – 16 times better than existing high-power systems, making it possible to detect objects as small and fine as a herring bone. The system is also modular, allowing hardware and software components to be adapted to suit the needs of

any producer in the food industry. “Most X-ray luggage scanners at airports are virtually identical because one type works anywhere,” Rheinlænder explains. “In the food industry, however, everyone has different requirements depending on the speed of the production line, the type and size of products being scanned and hygiene regulations.” The consortium of companies involved in the project has already sold three of their systems to companies in Spain, the United Kingdom and Denmark. The systems were bought after the project partners held a demonstration at the Scandinavian Food-PharmaTech exhibition last November in Denmark. Curiously, none of the three systems that were sold are being used in the food sector, confirming, in Rheinlænder’s view, the broader range of applications for the technology. In the UK, for example, the system is being used by a company to inspect filters delivered by an outside supplier, while in Denmark it is being used to check the quality of fur used to make coats. “The market for this technology is truly enormous,” he says. “In the food industry alone we can expect growth rates in excess of 20%… and we also see a market for using it in manufacturing, to inspect seals on car components, for example, or to check for counterfeit products.” G Adapted from materials supplied by ICT Results http://cordis.europa.eu/ictresults

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Material Testing

So that they keep flying
Testing machines and systems: we have the know-how.
picture: www.photocase.de

Knowledgeable people trust themselves and the safety reserves of the materials. Destructive testing of materials shows its limits, making safety measurable.

METROLOGY INTERNATIONAL LTD 8 COLD BATH RD, HARROGATE, HG2 ONA Send us an email Metrology.uk@btconnect.com Visit our website: www.metrologyinternational.com

Zwick GmbH & Co. KG August-Nagel-Straße 11 D-89079 Ulm/Germany Phone: +49(0)7305-100 Fax: +49(0)7305-10200 info@zwickroell.eu www.zwick.com

Intelligent testing
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PRODUCTS MATERIALS TESTING

intelligent wizards and context sensitive system. www.zwick.com

30 times faster set up
Latest developments of the IMETRUM Video Gauge enable it to achieve strain measurement accuracy in line with conventional strain gauges and resolutions down to 5 microstrain. These developments are available with both the desktop system and laptop based portable system. Early adopters of the technology have found the system 30 times quicker to set up than existing technology with the added advantage that the system is capable of producing considerably more empirical data. Independent benchmark tests have shown the technology to have an order of magnitude better resolution than other DIC systems. The Video Gauge is frequently used to overcome challenging measurement problems such as high temperature or high-speed material testing. For straightforward tasks such as batch testing of material properties it offers significant time and cost savings over traditional methods. www.imetrum.com

operation is further aided by the tester’s long battery life – 16 hours between charges. Exploiting the Leeb principle, the highly accurate (+/- 0.5% at 800 HL) hardness tester’s features include: an easy to read, large format digital display showing instantaneous measured results with optional statistical information, conversions to common hardness sales HV, HB, HRC, HRB, HRA, HS plus tensile strength and direct keys for the rapid setting of the units test parameters. www.bowers.co.uk

Rocky 2000 Rockwell hardness tester’
MAPRA Technik Co. have been appointed as official agents in the U.K. and Eire for GNEHM AG of Switzerland. The GNEHM range includes the latest GNEHM Rocky 2000 Rockwell Hardness Tester. This

Do toys pose a risk for our children?
A toy is defined in law as a product intended for children under 14 to play with. Every year thousands of new toys enter the market and as parents we don’t expect them to harm our children, but how can we be sure? Since January 1, 1990, toys can only be placed in the European market if they bear the CE Mark. Toy manufacturers are therefore under a legal obligation to ensure that their products are thoroughly tested, and they and their dealers have special tests performed by organisations such as LGA in Nuremberg, Germany. After successful results the LGA can also award the GS (geprüfte Sicherheit = certified safety) mark. Using a Zwick Z005 testing machine equipped with a 500N load cell, LGA carries out many mechanical tests which enable everyday situations which might arise in the playground or home to be simulated in the laboratory under controlled conditions. One example is when a child tugs at a stuffed dog’s muzzle with its teeth. The muzzle must remain fully attached even when a tensile load of 90N (9kg / 20lbs) is applied using the Zwick machine. With other toys it is absolutely vital that no small parts can become detached, as swallowing them can be

fatal for children. Subjecting parts of the toy to such pulling, pushing, tearing, bending, and cycling forces is child’s play using latest Zwick’s testXpert® II software because all the important parameters of the test machine such as crosshead speed, travel distances, required force limits, and loading profiles can be setup and stored in the software. Accuracy and consistency are so important and LGA benefits from the wide range of applications which are possible from a single load cell. For example, the 500N (112 lb) load cell achieves ISO 7500 Class 1 down to a lower limit of 1N (0.22 lbs). This means that forces measured at 1N have an accuracy of 0.01N (0.0022 lbs). This saves the time and cost of purchasing and setting up secondary load cells. In addition to mechanical and physical tests on toys LGA also performs chemical tests and checks for flammability, conformity with LFGB (food safety legislation), electrical safety, electromagnetic compatibility (EMC), radio frequency authorisation and hygiene. The flexibility of the Zwick machine means that it can be equipped with various sensors, tools and fixtures. Control and evaluation of the tests is performed automatically by the testXpert II software. The operator can quickly perform widely differing tests due to the

Entry level portable hardness tester
CV Instruments of the Bowers Metrology Group has a new entry-level portable hardness tester, the TH110. Ideal for both workshop or in-the-field operation, the cost effective ABS unit features a robust antishock casing, a sealed keypad and a convenient integrated thermal printer. Autonomy of

Analogue tester is made of sturdy steel construction and provides simple and cost-effective Rockwell hardness measurement according to DIN EN ISO 6508, ASTM for the standard test procedures HRA, HRB and HRC, etc. The tester is suitable for single and serial testing. The Preliminary Test Force is 98.07 N (10 kp), and then Test Force 588.4 – 980.7 – 1471 N (60 – 100 – 150 kp). The Test Force choice is by knurling tool wheel. It is supplied with a range of Anvils, Indentors and other accessories, including works calibrated comparison plates (HRC, HRB). www.mapra.co.uk QMT September 08

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INSPEX PREVIEW

Inspex 2008 focuses on quality
Inspex 2008 is the event for the UK’s quality manufacturing professionals to check out the latest in test, measurement, and inspection technologies.

I

nspex 2008, the event for the quality control and measurement industries, takes place within the Interplas exhibition being held at the NEC, Birmingham from September 30th to October 2nd. Companies taking part in Inspex 2008 include Alcatel Vacuum Technology, 3D Xray, GE Inspection Technologies, Hanatek, Konica Minolta, Mecmesin, MHH Engineering, OGP UK, Olympus Industrial, Tinius Olsen and X-rite. A special free seminar programme will provide a focal point for Inspex. Organised by the National Physical Laboratory, the Inspex seminars will offer two daily sessions, the first providing an introduction to a new measurement system for

Materials testing company, Tinius Olsen will be introducing 12 new products at Inspex 2008 QMT September 08 www.qmtmag.com

high-speed, high accuracy calibration and verification of CMMs, CNC machine tools and other leading-edge measurement applications. The second will offer advice on how companies can develop their business and uphold the highest measurement quality standards. As part of Interplas, the UK’s largest plastics and rubber exhibition, Inspex visitors will be able to take advantage of the extensive free Interplas seminar programme. The Interplas seminar programme will focus on three different themes over the three days of the exhibition - Sustainability & the Environment; Design & Innovation with Polymers; and the Past, Present and Future of Plastics. Notable topics covered include Energy Management in Plastics Processing and How The Carbon Trust Can Help Your Business. Full details of the seminar programme can be found on the Interplas website (www.interplas-expo.co.uk/programme). Visitors who pre-register for Interplas and Inspex also have the opportunity to win one of three daily prizes during the exhibition – a weekend for two in Paris, a supercar driving experience or a 42” HD ready plasma television. To enter, each visitor needs to register online at www.interplasexpo.co.uk and then visit the PMMDA stand to

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INSPEX PREVIEW

Right - OGP SmartScope Flash 200 video

drop his or her business card into a box. And as ever at such a major event, there will be plenty of new developments on show. Materials testing equipment experts Tinius Olsen, (www.tiniusolsen.com) will be announcing the addition of 12 new developments to their extensive range of testing equipment, while Sikora, (www.sikora.net) a worldwide specialist in meas-

Incorporating enhancements to its design and functionality, the MultiTest-d works in conjunction with a digital force gauge and forms an ideal entry-level motorised test system for professionals who wish to evaluate quality control parameters of their products in tension and compression. On show from OGP (www.ogpuk.com) will be its SmartScope Flash 200 video and multi sensor bench top measuring system, which offers high accuracy and ease of use. The compact machine will display its versatile capabilities by measuring a wide variety of injection moulded components. The company says its SmartScope Flash 200 with TTL laser benefits from a number of patented technological innovations that not only deliver consistently high levels of accuracy, but also offer user-friendly programming and operator functions.

uring and control equipment for the hose, tube, wire and cable industries, will also be showing several new products, including the LED 8025 XY. The LED-based system is the first diameter-measuring device, which also measures the eccentricity of transparent products with highest precision. Mecmesin, (www.mecmesin.com) a leading force & torque test solutions manufacturer, has launched its new MultiTest-d test system.

Mecmesin will show its new MultiTest-d test system.

X-Rite Inc. (www.xrite.com) will be showing its just-launched xDNA system with MA98 handheld spectrophotometer that can save automotive manufacturers and suppliers considerable time and money in applying metallic flake and other special effect paints. The xDNA package solves an ongoing automotive problem of how to accurately measure the colour and appearance of coatings with ‘sparkle’ that confound optical instruments. Key to xDNA are a new instrument called the MA98 that uses twice the number of illumination angles and sensors of previous instruments, and a software package called X-ColorQC that manipulates the data with proprietary xDNA algorithms to generate easy-to-understand graphs that show unique characteristics of an effect paint. G www.inspex.co.uk

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www.inspex.co.uk

Car parkin Inspex is F g at REE

The showcase for quality control in UK manufacturing
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