Online Metrology Intelligent control for a modern manufacturing process. 26/11/2018 Slide 1

Transcription

1 Online Metrology Intelligent control for a modern manufacturing process Slide 1

2 As a Solution partner, our strength is our deep understanding of manufacturing processes and increasing productivity by different précised means. Amit K. Choudhary Business Manager India Measurement & Automation Products Division Slide 2

3 Current Market Status Majority of auto OEMs are retooling the lines to meet BSIV to BSVI transition Tolerances are getting tighter Volumes are increasing drastically Industries are striving towards Industry 4.0 Every one wants to eliminate human error and automate processes. Slide 3

4 Is it just the case of Buying more equipment (machines, robots, etc.), employing more people Buying smart & intelligent machines? What do we mean by these smart machines? How are they different than what we have on our shop floor today? Are they any different?? as hope OR Are we looking at Industry 4.0 opportunity? 4

5 Industry current requirement's & key objective s S.No Production Quality 1 In process Setting of Tool wear drifts To eliminate bottle neck at CMM Lab. 2 Zero rejection To supply inspection data asap to help production give correction 3 In process setting of Position drifts w.r.t drawing datums To check parts as per quality drawing inclusive of dimensional and GD&T parameters like circularity, flatness etc. 4 Having inspection data at Point of manufacturing To record data for future traceability 5 Operation wise data to avoid taking any action correction before going for next OP 6 Lesser dependency on end of line inspection just for segregating parts for OK and Not OK 7 Achieve better Cp & Cpk values always. Slide 5

6 Current Manufacturing Process Slide 6

7 What do you think, Will adding Robots and automating the material handling will solve the issue? 7

8 However there is a difference in automating machine tending and automating the complete process Slide 8

9 Hurdles that can occur in an automated transfer line Slide 9

10 Elements affecting majorly in any automated line Slide 10

11 Temperature fluctuations on shop floor over the day and months Slide 11

12 Other factors that causes process variations are Tool wear Machine thermal dynamics Environment Material Slide 12

13 Robots and automation alone cannot meet the required yield Even though we believe we are becoming more efficient, we are in-fact decreasing efficiencies

14 Process control is THE ONLY way to achieve greater efficiency

15 What is the Renishaw Equator Gauge? Consider inspection on the shop-floor Slide 15

16 What is the Renishaw Equator Gauge? Equator is a comparative gauge Not an absolute metrology device like a CMM. A comparator for medium to high volume gauging Robust proven on the shop-floor and thermally insensitive Versatile - Able to switch between multiple parts (Not Tailor made like multi gauge) In Process Tool Wear compensator In Process Position (w.r.t. different datums) compensator Form measurement at Shop Floor (GD&T) Slide 16

17 The role of Renishaw Equator Systems on the shop-floor As a standalone Gauging System Allows manual or automatic in-process corrections at point of manufacture Targets key manufacturing operations Reduces the need for end of line sample inspection for QA As part of an Automated Cell Delivers all the benefits of a standalone Equator Connection to robots and controllers eliminates human error and boosts throughput Parts can be sorted and palletised Full lights-out manufacturing is achievable Slide 17

18 Traditional manufacturing Environment High labour cost Low productivity Skilled operators High quality costs Queuing Remote QC area

19 Major Challenges to incorporate automated process control Slide 19

20 Current Manufacturing Process Slide 20

21 How Equator can make a difference? How Equator can play a vital role Can Inspect part just after manufacturing (100 plus Equator running in Indian shop floor, also more than 4000 Equators running globally) Get RESULTS AT POINT OF MANUFACTURING Multiple form of results can be displayed 1. Results wrt to quality drawing similar to what you get from high end scanning CMM 2. Results wrt to production / process setting drawing. (For eg. Production supervisor will not be much interested to learn what the parallelism is between to opposite planes, rather he will be interested to know the Angle between planes to take corrective action) 3. Tool Wear data (eg CNC No 045 Tool No 5 Wear 30 microns, height 10 microns) 4. Position control data (eg CNC No 045 Line no 65 G54 needs a correction of 68 microns in X and 48 microns in Y) 5. Live update of the process flow. Slide 21

22 Smart Factory Process flow In Line Process Control Ultimately what we want is to manufacture all OK parts as close to nominals and have better Cp & Cpk 1. Inspect every 3 th or 5 th part coming out from Line. 2. Only inspect CTQ parameters Cover only tight tol features TOOL wise. Eg. If 9 tools required for manufacturing crank case than measure only 9 features having tight tolerance. 3. Update Tool Wear from the results 4. Update Positions wrt datums and distances from the results. Post Process Verification / Certification Inspect all parameters on CMM once a week/fortnight.(customer can decide frequency) Slide 22

23 Future factory our view Direct process control High productivity Highly automated Low labour costs Intelligent manufacturing Lower quality costs

24 IPC Intelligent Process Control Software Slide 24

25 PROCESS CONTROL SOLUTION FOR CRANK CASE Post process Monitoring In process Control Process setting Frequency based inspection of all parameter Thermal Growth in Z Axis 100% inspection on Shop floor Tool setting COMPONENT Details Process Foundation Machine health checkup (Pitch error) Cockpit Cockpit LH Crankcase Line OP10 OP10 OP20 OP20 OP30 RH Crankcase Line Quality Gate with OK Marking Washing M/c Quality Gate with OK Marking Challenges in crank case manufacturing Bore size Coordinates Milling Height/Depth R face Conventional method CMM, Multi Gauge, Height Gauge, Air Gauge, Zoller Tool setter

26 PROCESS CONTROL SOLUTION FOR CRANK CASE COMPONENT Details Challenges in crank case manufacturing Bore size Coordinates Milling Height/Depth R face Conventional method CMM, Multi Gauge, Height Gauge, Air Gauge, Zoller Tool setter Alternate solution used in the industry LH Crankcase Line Cockpit Gauging for LH Gauging for RH Cockpit OP10 OP20 OP30 RH Crankcase Line Washing M/c Quality Gate with OK Marking Comparison against Equator Two gauging system required Investment up 40L Every year calibration & AMC No provision to add feature No GD&T feature inspection Not feasible to check coordinates (Dependency on CMM) Suitable only for dedicated component

27 Intelligent Process Control Renishaw Process control solution : Equator 500 with IPC OP 30/40 Mazak J500 Vari axis Line 1 OP20 Mazak VMC OP20 Mazak VMC OP20 Mazak VMC OP20 Mazak VMC Intelligent Process Control Line 2 OP20 Doosan VMC OP20 Doosan VMC OP10 Doosan VMC OP10 Doosan VMC SPC Display screen 1 OP10 Mazak VTL SPC Display screen 2

28 Process Control solutions for 5C Slide 28

29 The Solution Process for Transmission shaft First part Cut a part Measure the part Calculate the tool offset Automatically feed back 100% of tool offset Slide 29

30 The Solution Process All other parts Continuously cut parts Measure the parts Calculate average tool offset of X parts Automatically feed back ~70-100% of tool offset Slide 30

31 Tool Offset Window in Equator Slide 31

32 Example IPC One to One Ethernet cable Slide 32

33 Automated close loop feedback for Tool Offset Tool Offset Window in Equator confirming the offset value, Tool No and Machine. Tool Offset Window in Machine Tool Controller confirming the offset value, Tool No and Machine. Slide 33

34 Close loop feedback for Tool Offset ensuring consistently controlled process Slide 34

35 Slide 35

36 Industry current requirement's & key objective s S.No Production Quality 1 In process Setting of Tool wear drifts To eliminate bottle neck at CMM Lab. 2 Zero rejection To supply inspection data asap to help production give correction 3 In process setting of Position drifts w.r.t drawing datums To check parts as per quality drawing inclusive of dimensional and GD&T parameters like circularity, flatness etc. 4 Having inspection data at Point of manufacturing To record data for future traceability 5 Operation wise data to avoid taking any action correction before going for next OP 6 Lesser dependency on end of line inspection just for segregating parts for OK and Not OK 7 Achieve better Cp & Cpk values always. Slide 36

37 How Renishaw will help meeting the objectives S.No Production Renishaw Remarks 1 In process Setting of Tool wear drifts Can get exact data for Tool wear, can be compensated either manual or automatically using IPC software 2 Zero rejection In collaboration with EQ and MT Probe which will take part work offset precisely, we can achieve Zero rejection 3 In process setting of Position drifts w.r.t drawing datums 4 Having inspection data at Point of manufacturing Yes 5 Operation wise data to avoid taking any action correction before going for next OP 6 Lesser dependency on end of line inspection just for segregating parts for OK and Not OK 7 Achieve better Cp & Cpk values always. Yes Possible with EQ Possible, Single EQ can be utilized in a cell of all 8 machines. Not required at all, as we will be having report of full parameters as well Slide 37

38 How Renishaw will help meeting the objectives S.No Quality Renishaw Remarks 1 To eliminate bottle neck at CMM Lab. Yes as the measurement cycle time is way faster than CMM and not required control temp of 20 degrees, it can take all load of CMM 2 To supply inspection data asap to help production give correction 3 To check parts as per quality drawing inclusive of dimensional and GD&T parameters like circularity, flatness etc. 4 To record data for future traceability Possible Yes Instant data at Point of manufacturing available Possible, It has same CMM software and can output results at par with any CMM 5 To have a secondary support (Shop floor CMM) at par to help sharing load at Lab CMM Equator plays dual role of In process setting at the shop floor also measures part unlike CMM thus catering requirements from both departments. Slide 38

39 Thank you Slide 39