The quality of the products a company produces, and their assurance of that quality, can mean all the difference to successfully acquiring contracts. Maintaining that quality also significantly increases the chances of repeat business. High-Tech Engineering, a precision engineering company based in Dunstable, Bedfordshire, UK, has always focused on the quality of the parts it produces. Now with its latest addition, a Renishaw Equator gauging system, it is reaching 100% part inspection and zero scrap whilst halving the operator requirements and reducing part production costs by 27%.

Started in 1985 by Managing Director, Steve Tickner, High-Tech Engineering built a reputation in the motorsport industry for delivering high quality machined parts. The company has since moved into the aerospace sector and gained some key industry approvals, including becoming a preferred supplier to Rolls-Royce and BAE Systems.

Recently High-Tech won a contract to produce precision milled titanium parts for a large aerospace customer. Due to the nature of the parts, High-Tech was instructed to carry out
100% part inspection. Steve Tickner explains, “We knew from the start that we would need to find an inspection method which could not only meet the cycle time requirements for the part, but would be a cost effective solution for us as well. Relying on the CMM we already had wasn’t going to be an option. We couldn’t risk any bottlenecks. We knew that we would either need another CMM or something else which could give us the measuring capacity. That’s what led us to the Renishaw Equator.”

Equator gauging system acquisition

It was through a simple internet search that Steve came to learn of the Equator gauging system. After some research and following meetings with representatives from Renishaw, High-Tech was impressed with what the Equator gauging system could offer, and was particularly pleased with the overall price of the system.

Commenting on why High-Tech bought the Renishaw Equator gauging system, Steve says: “Space on our factory floor is at a premium. Within the space we set aside for this cell we had to include faster, more efficient technology. This meant that a co-ordinate measuring machine (CMM) with a temperature controlled environment was far too big to be practical. The Equator suited the space perfectly as it’s a compact machine. The added bonus is the fact it is thermally insensitive and doesn’t require any air supply, meaning we didn’t need to spend additional time, money and effort putting in another temperature controlled room or extra piping.”

High-Tech is currently using the Renishaw Equator gauging system to perform 100% inspection of a complex aerospace part. It works by comparing the manufactured parts against a matching master part, gauging all the features in a single operation with an immediate pass/fail decision, along with a report of the component dimensions.

Comprehensive measurement in half the time of the existing CMM option

The Equator gauging system is used to gauge around 150 features including a number of bores, thicknesses and form measurements on the part with typical tolerances of ±25 µm. The Equator gauging system does this within 10 minutes and well within the production requirements, far less than the machining time. This is almost a 50% reduction in cycle time compared to running the program on High-Tech’s CMMs.

Process control, run by the machine tool operator

Production at High-Tech runs 24 hours per day, 5 days per week and is split into 2 overlapping shifts. During this time Equator is used by a number of operators with varying skill sets. Previously, High-Tech Engineering would have relied on its CMMs, housed away from the machine tool in a temperature-controlled quality room. Using the CMM for the latest job would have involved two separate operators, firstly the operator machining the part and secondly the operator with the specialist skills to operate the CMM. By using an Equator instead, newly trained staff can use dimensions from a certified component, approved by the QC operators, to “zero” the Equator gauging system and set its accuracy for subsequent measurements. This has allowed the same operator who machined the part to measure the part, halving the operator time required.

Flexibility and future proofing

The Equator gauging system is fully programmable and can be used on multiple parts, meaning High-Tech Engineering can perform highly repeatable and rapid automated routines across numerous contracts resulting in significantly reduced labour costs.

Ease of use – push-button simplicity

Commenting on this, Mr Tickner states, “All of the operators can use Equator. It really is easy; just load the part and push the button. It completely simplifies the process and frees up manpower, which in turn helps to deliver ROI very rapidly for the cell.”

High-Tech has managed to reduce the cost of producing the aerospace part by 27% with the Equator gauging system being a factor in that. This has had a real impact on the competitiveness of this sort of production, allowing the company to make the same precision quality parts, whilst also delivering better value to its customers. It is through implementing these types of solutions and continually striving to improve their processes that High-Tech has been awarded 6 consecutive SC21 silver awards, which is unrivalled in the UK. This award recognises excellence within the aerospace and defence industry, for the quality of the products a company produces, as well as its ability to supply them. To receive a silver award a company must consistently achieve at least 95% for delivery performance and at least 99.5% on quality of parts to all of its customers.
Mr Tickner explains “Since we started using Equator we have not made a single bad part. The Equator is allowing the operators to operate complete process control. They all look at the Process Monitor screen, part of the Equator software, which lists all of the features being gauged. Next to the feature name there is a little bar which turns from green to amber to red as the size or location for each feature begins to drift. The operators know which tool on the machine is responsible for each feature and so can take corrective measures to occasionally tweak the process, to come back well within tolerance. As we carry out 100% inspection, it would be very hard to make a part wrong.” He continues, “We are also using the gauge data to trial different types of tool, to see which gives us the best level of efficiency – something which might save us more money in the future.”

Outlook

Following the success of this manufacturing cell, Mr Tickner plans to use the Equator gauging system as part of future cells he will be commissioning for jobs in the pipeline. He concludes: “When you find something which helps you make a perfect part every time, reduces manpower commitments, reduces overall costs and doesn’t cost a fortune itself, it’s a winning solution. All of the benefits are passed on to our customers who know they are getting the best quality at the best price”.

At the Diemould exhibition taking place at Bangalore International Exhibition Centre, Bangalore, India, from 6-9 April, Renishaw (hall 2A stand B38) will highlight a range of process control solutions that help tackle the increasing drive to lean manufacturing, from new technologies for pre-process machine calibration, to on-line and off-line post-process measurement. There will also be a significant focus on the company’s additive manufacturing (3D printing) systems with the new PlusPac upgrade for its AM250 additive manufacturing machine.

The company will have active demonstrations of its Equator gauging system along with various machine tool software’s catering to Diemould industry.

Renishaw is the UK’s only manufacturer of a machine that ‘prints’ metal parts and visitors to the Renishaw stand will be able to see applications that demonstrate the capabilities of the company’s additive manufacturing technology and Strain gauge high-accuracy machine tool touch probes – Unparalleled accuracy and repeatability make this technology the best choice for complex multi-axis work and machine calibration .

RENGAGE technology
RENGAGE technology delivers true three dimensional (3D) measurement performance and submicron repeatability. So for exceptional performance, reliability and durability, why choose anything less? Conventional probes continue to fulfil a valuable role, which is why Renishaw maintains its position as market leader in the design, manufacture and support of these products.

However, for numerous applications, the significant performance benefits offered by RENGAGE technology provide users with a competitive advantage, for both now and the future.

RENGAGE technology is available with radio transmission in the RMP600; with optical transmission in the ultra-compact OMP400 and compact OMP600; and in the miniature MP250, offering an unmatched combination of size and accuracy.

The Primo system – opening up the world of precision manufacturing
At Diemould Renishaw is highlighting the Primo system: an entry‑level machine tool probing system that opens up the world of precision manufacturing to all types of manufacturing operation.

A genuine breakthrough business model, the Primo system makes it easy for manufacturers to take their first steps towards higher-value manufacturing by automating their operations and achieving repeatable processes.

Renishaw fixtures: the new single source for metrology fixturing
Following the acquisition of R&R Sales LLC in 2012, Renishaw has developed an extensive new range of modular fixturing designed specifically for co-ordinate measuring machines (CMMs), vision systems and its Equator gauging system. Visitors to Diemould 2016 will see that the new range offers a wide choice of base plates and components available in M4, M6 and M8 thread sizes, and can be utilised for measurement applications across multiple industries, such as aerospace, automotive and medical.

Automated gauging and process monitoring software for the Equator gauge
Renishaw Equator, a lightweight, fast and highly repeatable gauge, will be demonstrated in an automated cell. Equator’s innovative flexible gauging technology is based on the comparison of production parts to a reference master part, which can greatly increase throughput and reduce scrap rates at a fraction of the cost of an equivalent custom gauging system. Equator can switch between parts in seconds, perfect for flexible manufacturing processes or accepting parts from multiple machines.

A new process monitoring window has also been added to the shop-floor user interface for the Equator gauging system. This instantly displays measurement results of inspected features to the operator on a bar-graph display. It also shows the history of measurement on each feature so that process trends can be seen. The system’s re-mastering process can now be managed based on temperature limits, number of parts or time since last master.

Enhancements in metal 3D printing
Visitors to Diemould will also see a new range of additive manufacturing technologies. Renishaw’s laser melting systems utilise a pioneering, additive manufacturing process capable of producing fully dense metal parts direct from 3D CAD, using a high-powered fibre laser. Parts are built from a range of fine metal powders that are fully melted in a tightly controlled atmosphere, in layer thicknesses ranging from 20 to 100 microns.

The AM250, Renishaw’s first additive manufacturing machine is now available with PlusPac – an add-on kit which transforms the machine to meet the demand for cleaner process environments, improved surface finish and precision. PlusPac includes new Optical Control Software (OCS), a gas knife lens window protection system, and a high capacity filtration system. These updates give the user tighter control over the build process, enabling users to create even better components.

Kishan Auto parts Pvt. Ltd., Rajkot (Gujarat, India) is a world leader in the manufacture of connecting rods for major names in the car, compressor, heavy commercial vehicle, tractor, marine engine and earth mover manufacturing industries. Kishan recently purchased a Renishaw Equator flexible gauging comparator, and have seen an immediate reduction in cost and gauging cycle times of more than 80%.

Additionally, despite shop floor temperature variations of more than 21 °C (43 °F), measuring performance has been unaffected due to Equator’s unique comparator method which uses master parts calibrated on Kishan’s co-ordinate measuring machine (CMM).

Versatile gauging on the shop floor
Con-rod master being ‘calibrated’ on a CMM in a temperature controlled roomKishan Auto is now using Equator to gauge multiple variants of connecting rods, and is adding more every day. Typical gauging times of 55 seconds per connecting rod are a significant

reduction over previous methods. The operators can use one Equator machine for many different parts, gauging all the features in a single operation with an immediate pass/fail decision, along with a report of the component dimensions.

Despite its location in Rajkot, Gujarat, where temperatures soar to 40 °C (104 °F) and drop to 19 °C (66 °F), Kishan is seeing repeatable results from its Equator system. This is achieved by re-mastering at least every 3 hours, or when they know the temperature has changed significantly – ‘re-zeroing’ the system removes the effect of thermal growth from the measurements, and therefore guarantees component quality.

The master part must be kept close to the machine and subject to the same thermal conditions as the production parts. If at any time the ambient temperature changes rapidly and a part goes out of tolerance, an operator can measure the master part to re-set the system and check the reported ‘fail’ is not due to the environment.

Traceability and extra capacity
Mr Changela, MD Kishan AutoThe master parts are ‘calibrated’ on Kishan’s CMM, which gives them the traceable accuracy they rely on to guarantee quality. However, the high thermal variation means that the CMM has to be used within the company’s temperature-controlled room. Equator gives Kishan the opportunity to extend the certified accuracy to the shop floor whatever the conditions. For this particular requirement, Equator has removed the need to purchase an additional CMM with scanning capability, as Mr Shantibhai Changela, Managing Director at Kishan Auto, comments, “Essentially Equator and the CMM complement each other perfectly, one providing the traceable certified accuracy, the other providing the thermal capability and extra capacity.”

Before Equator
For many years Kishan Auto has been using air gauges for checking diameter, circularity and ‘bend and twist’. For each of 360 variants of connecting rod they have used 3 or 4 different gauges. On larger connecting rods for heavy use applications, this can be at a 100% sample rate.

In Kishan’s experience these hard gauges usually last up to 10,000 uses, and then have to be reworked. For each different connecting rod, 3 of the 4 gauges cost Rs 6,000 (approx US $120), while the display costs Rs 30,000 (approx US$ 600). However with the 4th gauge, measuring ‘bend and twist’, the cost goes up to around Rs 300,000 (approx US $6000) – this includes a golden part which can be easily damaged and often has to be replaced.

In addition the whole process can take 120 seconds for each air gauge, so for each part tested the whole process can take more than 8 minutes. With increased demand for their products Kishan needed a faster method of gauging.

The search for a fast inspection system
Kishan conrod on Equator 300During September 2011 managers from Kishan Auto were in Germany for business meetings and to visit the EMO Hannover exhibition. Having searched without success for more than 2 years for an inspection system that could achieve the speed of operation they required, they did not have high hopes of finding a solution. It was only as they were on the point of leaving the show that they spotted one of the Equator system demonstrations on the Renishaw stand which was gauging a connecting rod – it was a chance encounter that ultimately solved their problems. They requested a demonstration within a few days of returning to India, and having seen an Equator gauging their own parts, immediately decided to purchase a system.

Cutting the cost of gauging
Time and ability to cope with temperature are not the only issues for Kishan Auto; more important is the cost of gauging. They have identified 77 variants of connecting rods which the Equator system can accommodate, and operators use the system to measure 500 units per day in a 10 hour shift. If Kishan Auto were to invest in hard gauging for all 77 variants, it would mean an investment of Rs 23 millions (approx US $450,000), just for the hardware alone. There are also other costs to consider, such as skilled labour to set up and maintain these gauges, storage, and running costs.

Kishan goes from strength to strength
Kishan Auto operator using Equator gauging systemThe company was started by Mr. Changela in 1988. Kishan started by manufacturing 2,000 connecting rods per month and today they manufacture up to 50,000 per month with 360 variants. The customer list reads like a who’s who in the world of cars, compressors, heavy commercial vehicles, tractors, marine engines and earth movers.

Kishan exports 90% of its production to leading industrial and developed nations including the USA, UK, Germany, Singapore, Italy, China, Poland, Brazil, and the Netherlands. The company has a reputation for high quality within required tolerances, but also at a competitive price. It specialises in manufacturing connecting rods from raw material to finished product within their own forging plants, with a lead time of 60 – 90 days.

Top Quality is Kishan Auto’s mantra
For Kishan, quality is the result of the right work ethic and processes for both management and operators, plus having the right equipment to achieve the required aims. The introduction of the Renishaw Equator gauging system has significantly enhanced quality, such that the company is now in a position to operate 100% inspection of components, quickly and easily, and are happy to guarantee 100% quality assurance on all parts.

As Mr Changela comments “Quality is critical to us, we constantly strive to achieve 100% quality, at the same time as improving efficiency and passing those savings on to the customer. Equator has taken us to another level.”

Courtesy: Renishaw Plc