Implementing Advanced Coordinate Measuring Machine Systems for Precision Manufacturing
Summary
A leading aerospace components manufacturer transformed their quality control operations by implementing a comprehensive coordinate measuring machine (CMM) system, reducing dimensional inspection time by 75% while achieving 99.97% measurement accuracy. The integration of automated CMM systems with statistical process control eliminated critical dimensional defects and established real-time quality monitoring across production lines.
The Challenge
Initial Need:
Boeing's Tier 1 supplier, Precision Aerospace Components (PAC), faced mounting pressure to meet increasingly stringent dimensional tolerances for critical flight components while maintaining production schedules. Their existing manual inspection processes using hand tools and basic measuring equipment were consuming 40% of total production time, creating bottlenecks that threatened delivery commitments. With aerospace industry requirements demanding tolerances within ±0.0002 inches (±0.005mm) for critical components and complete dimensional verification of complex geometries, the company needed a systematic approach to quality control that could deliver both speed and accuracy.
Pain Points:
Inspection bottlenecks: Manual dimensional inspection consuming 40% of total production time across 12 production lines
Measurement inconsistency: Human operator variability resulting in ±0.0008" measurement uncertainty, exceeding acceptable tolerance bands
Limited geometric capability: Inability to measure complex 3D geometries and form tolerances required for turbine blade components
Rework costs: 8.5% rejection rate due to dimensional non-conformance, resulting in $2.3M annual scrap and rework expenses
Our Solution
Our Approach:
PAC implemented a comprehensive CMM-based quality control system centered around three Hexagon Global Performance CMM units with PC-DMIS software integration. The solution included automated part loading systems, environmental controls, and real-time data integration with their existing ERP system. The implementation strategy focused on establishing a centralized measurement center with satellite CMM stations positioned strategically throughout the production floor.
Methodology:
The implementation methodology began with comprehensive measurement system analysis (MSA) studies to establish baseline capabilities and identify critical measurement points throughout the production process. Part programming was standardized using feature-based measurement routines, incorporating GD&T callouts directly from engineering drawings into automated inspection sequences. Statistical process control (SPC) integration enabled real-time monitoring of key dimensional characteristics.
Final Summary:
The comprehensive CMM implementation resulted in a transformation of PAC's quality control capabilities, achieving 99.97% measurement accuracy while reducing inspection cycle time from 45 minutes to 8 minutes per part. The system successfully eliminated dimensional defects that previously accounted for 85% of customer returns, while establishing real-time quality monitoring that enabled proactive process adjustments.
Execution
Process Description:
The execution phase began with facility preparation including installation of isolated foundation systems for the CMM units, implementation of temperature and humidity controls to maintain 20°C ±1°C environment, and establishment of vibration isolation systems. Programming development involved creating standardized measurement routines for 47 different part families, incorporating automated probe changing systems and part recognition capabilities.
Outcome
Value Comparison:
The CMM implementation delivered measurable improvements across all quality metrics, with dimensional inspection time reduced from 45 minutes to 8 minutes per part, representing a 75% improvement in throughput efficiency. Measurement accuracy improved from ±0.0008" uncertainty to ±0.00008", providing a 10x improvement in measurement capability that exceeded customer requirements. The rejection rate decreased from 8.5% to 0.3%, eliminating $2.1M in annual scrap and rework costs.
Client Testimonial:
"The CMM implementation has fundamentally transformed our quality control capabilities and customer confidence in our products. We've eliminated dimensional defects that previously caused customer returns while dramatically reducing inspection time and costs. The real-time statistical monitoring gives us unprecedented visibility into our processes, allowing us to maintain consistent quality while meeting aggressive delivery schedules."
- Sarah Mitchell, Director of Quality Assurance, Precision Aerospace Components