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Technical innovation and quality of the products are the main strategies of a fast growing company. The survival of any company in current competitive world is possible only if it provides highly precise and quality products which meet the customer requirements and satisfaction. In case of tool manufacturing company they need to focus to produce precise and accurate products.
The current report made with focus on improving quality of the products and to reduce scrap in short time. To solve existing metrology problems cost effective equipments were chosen. For checking the tolerance levels spindles suitable micrometer is selected. The report looks into the current metrology status in the company and its drawbacks. The report then suggests a solution of the old measuring systems and the new measuring components to be included in the measurement process and their brief description and justification for the decision taken into consideration the cost involved with purchase of new measuring instruments and special building facilities required and keeping the production and inspection timescale to minimum. The factors like costs involved and the new equipment required has been explained, timescales for production and inspection and the time for installation of new equipment have been explained using a Gantt chart
Current metrology scenario of the company
The current metrology room of the company has a good temperature control of +/- 2 degrees and cleanliness is ensured. A coordinate measuring machine (CMM) with a working volume of 1.7m x 1.1m x 0.7m is housed in the metrology room which has a confined additional inspection capacity available in its operation module. It also has two other metrology stations located on the shop floor which have spare capacity but lack temperature control and cleanliness cannot be guaranteed.
ANALYSIS OF THE CURRENT EQUIPMENT:
For the company to be recognized as one of the leading in market in providing high quality solutions, the company needs to implement the ISO standards 9001:2000. This would require an overhaul of all the major production processes development and maintaining of quality management systems, as defined in the ISO 9001:2000 guidelines.
The company's current metrology status has been analysed and some points which can be concluded are:
The additional inspection capacity of the coordinate measuring machine in its operating schedule is confined. No temperature control on the shop floor. The two other metrology stations located at the shop floor do not have temperature control. Lack of cleanliness at these two stations, makes it unsuitable for any new equipments to be housed for good performance and improvement in productivity. The present equipment gives a Clear picture of failure in finding the trend changes of the various equipments
To overcome the above mentioned problems certain action has been taken and the new equipment has been proposed to have quality and accuracy in production.
SOLUTION FOR THE REQUIRED TASK AND EQUIPMENTS PROPOSED:
SOLUTION FOR TASK-1:
Regular batch measurement of 50 small spindles whose diameters range from 5mm to 50mm and with a diametrical tolerances range of +/-20m to +/- 100m. Priority is for determination of whether in tolerance or not.
To achieve above requirements starrett bench micrometer is selected.
- Measuring range : 0 mm to 50 mm
- Accuracy : 25µm (maximum)
- Repeatability : 10µm
- Data : Dial/Direct Read
- Resolution : 0.02 mm
The base is a heavy, rigid casting, incorporating at the left end a movable anvil which actuates a linear, friction-free motion transfer mechanism between the anvil and the indicator. This assures high accuracy
The large thimble diameter, approximately 3" (77mm), makes possible widely spaced graduations that are easy to read without a vernier scale reference
Advanced, staggered design and quick reading graduations in combination with Starrett no-glare satin chrome finish on both thimble and sleeve also contribute to easier, faster readings
The head is furnished with a speeder and has a special ring-type lock nut which firmly holds the spindle at any setting without distortion
Another useful feature is the adjustable work table cantered beneath the anvil and spindle. Work can be accurately aligned between the anvil and spindle by adjusting the table to the proper height and locking it in position
The spindle and anvil are carbide faced for long life
SOLUTION FOR TASK-2:
Task 2 involves regular batch measurement of 5 bearing housing assemblies whose details are given below:
- Each assembly has 10 holes with diameters ranging from 5mm to 50mm.
- Diametrical tolerances range from 5mm up to 50mm
- Not necessary to record the actual tolerances, but a knowledge of whether in tolerance or not is required
- Considering the above conditions, a coordinate measuring machine is recommended which is discussed in detail in the following section.
SOLUTION FOR TASK-3:
Task 3 involves regular batch measurement of 5 torque shafts which should be straight along their length to a tolerance of +/- 24µm over their entire length of 800mm.Trends in straightness data must be monitored and trends in length data are used to monitor thermal variations.
Based on the details given, a CMM is proposed.
This involves measurements of small quantity one offs of high value bespoke pump assemblies whose dimensional data has to be recorded and tolerances are all to the ISO standards such as ISO 286-2(1986)
Considering the above conditions a coordinate measuring machine is proposed.
- Lower weight for more speed
- New, highly efficient air bearings
- Optional performance package
- Higher temperature independence thanks to F.I. technology
- Freely selectable measuring lab temperature (20-26°C)
- Maintenance-friendly design
- Larger measuring range
Reasons behind selection of the CMM:
Besides having a CMM, an additional CMM is proposed. The following are some of the reasons justifying the selection and advantages of the CMM chosen: as task 2 involves regular batch measurement of 5 bearing housing assemblies, so the new CMM can fast enough to measure more batches in short period. In task 3 trends in straightness data needs to be monitored as a part of predictive maintenance on certain production processes. Also trends in length data need to be monitored for thermal variations in the processes. In task 4, dimension data of the one-off's high value bespoke pump assemblies need to be recorded. All these data can be easily recorded and stored by programming the software that comes with the new CMM. This effectively eliminates the need for additional equipment to record the trends data. The new CMM has cost effective and its within the company budget. The existing CMM has limited additional capacity, the new CMM makes company to benefit from the lower procurement price and lower lifecycle costs. Operation time of the old CMM is very large which makes the process quite time consuming. The old CMMI does not meet the ISO standards. Software of the new CMM employed makes task3 and task4 easier which require monitoring of straightness data trends and recording the dimensional data. Temperature control and cleanliness can be ensured.
The company currently has a metrology room with good temperature control and cleanliness is ensured. Now the new CMM is to be installed in a room where in it can operate. However there are two other metrology stations located on the shop floor which can serve for the purpose.
The only suitable option is to house the new CMM in one of the additional metrology station which may need some modifications to achieve temperature control mechanism and cleanliness.
Temperature control can be achieved by installing air conditioning and cleanliness can be ensured by constructing a glass chamber.
Reason behind the selection of the MICROMETER:
As task 1 involves measurement of 50 spindles The Starrett No. 673 Bench Micrometer is a high precision instrument, ideal for bench use in company metrology station. It can be used as a comparator measuring to fifty-millionths of an inch (.000050") or two-thousandths of a mm (0.002mm) or fordirectmeasuring to .0001" or 0.002mm. Work lengths up to 2" or 50mm can be measured. This micrometer accurately checks whether the part is in tolerance level or not. It is one of the most accurate micrometers available. This micrometer having very high speed operation which requires very less time to measure the diameters of a batch of 50 spindles. It is very low cost and more reliable.
COSTS INVOLVED WITH THE NEW EQUIPMENTS:
The following costs are the approximate costs involved in purchasing and installation of the new equipment proposed:
NAME OF THE EQUIPMENT
Probe Styli with ball diameter 1mm
Air conditioning costs for metrology room
TOTAL COSTS = £ 31,890/-
The current report illustrates the company strategies to improve the quality of its products .The drawbacks of the old system have been identified and proper steps are suggested. The new equipment proposed has been justified and all the costs involved are calculated. The various facilities and modifications required are discussed in detail.
- Busch, T (2006). Dimensional Metrology. 3rd ed. London: Delmar Publishers.
- Figure 1: http://www.jwdonchin.com/Starrett/Catalog/BenchMics/673.html
- Figure 2: http://www.google.co.uk/imgres?imgurl=http://quad4x4.com/images/driveshaft%2520center%2520bearing%2520kits%2520010.jpg&imgrefurl=http://quad4x4.com/Dodge%2520Rear%2520Driveshaft%25201993%2520and%2520prior.htm&usg=__5UW2Cx_lujKrLNl25HVXZOlyZpU=&h=467&w=791&sz=18&hl=en&start=19&sig2=sbT3PVf4KLpVVH5uOyOwlQ&itbs=1&tbnid=ipjixkV6zI_gqM:&tbnh=84&tbnw=143&prev=/images%3Fq%3Dbearing%2Bassembly%26start%3D18%26hl%3Den%26sa%3DN%26gbv%3D2%26ndsp%3D18%26tbs%3Disch:1&ei=lJDLS8TfJpecOJzFyPUE
- Figure 3: http://www.google.co.uk/imgres?imgurl=http://www.atitelemetry.com/uploads/image/1_drive_shaft_torque_telemetry_system.jpg&imgrefurl=http://www.atitelemetry.com/viewproduct.php%3Fid%3D1%26appid%3D6&usg=__maUqDYupOtZebRnkLv6wsfFVlxQ=&h=233&w=350&sz=12&hl=en&start=16&sig2=4JBczz8YfNQFPBy4efAy-A&itbs=1&tbnid=C464wzQMu-Y9pM:&tbnh=80&tbnw=120&prev=/images%3Fq%3Dtorque%2Bshafts%26hl%3Den%26gbv%3D2%26tbs%3Disch:1&ei=U5HLS8K4HcaQONvV1PEE
- Figure 4: http://www.zeiss.ca/4125682000247242/Contents-Frame/7edf747371b0af68862570c70057a6c2