QUALITY MANUFACTURING TODAY - Allegiance Group, Inc.

40 Pages·2010·7.04 MB·English

QUALITY MANUFACTURING TODAY
www.qmtmag.com
November/December 2010
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NIKON METROLOGY NV
T [phone]
[email protected]
NIKON METROLOGY UK Ltd (Derby)
T [phone]
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NIKON METROLOGY I VISION BEYOND PRECISION
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p3 contents.qxp 18/11/2010 12:11 Page 16
CONTENTS
November/December 2010
News and comment 4
Stress-free quality 10
Portable laser-based measuring technology supports
quality improvement and production assembly at Swiss
aircraft manufacturer, Pilatus Flugzeugwerke.
Laser projectors speed Airbus A350 12
Carbon fibre challenge - up to 220 laser projectors will
ensure efficient production for the new Airbus A350 XWB.
FFrroonntt ccoovveerr::
HHeexxaaggoonn MMeettrroollooggyy LVMC’10 conference report 14
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How to quickly check your laser trackers for measure-
ment accuracy, understanding laser tracker targets and
speeding up large scale assembly of composite structures
- some of the topics at LVMC’10.
Editor - Publisher: BBrreennddaann CCooyynnee Automated metrology 16
Email: [email protected]
Tel: [phone]
Quality essentials 17
Media Director - Publisher: The strategic importance of quality management systems
DDaawwnn WWiissbbeeyy
in embedded markets such as aerospace. By Efstratios
Email: [email protected]
Petrellis, quality manager, MEN Mikro Elektronik.
Tel: [phone]
Mob: [phone]
Blinding quality 21
Website: www.qmtmag.com
The drive for profits in pharmaceutical and life science
QQuuaalliittyy MMaannuuffaaccttuurriinngg TTooddaayy, pub- businesses can blind senior management to the impact
lished eight times a year, is a print and supply chain quality has on company performance and
on-line magazine for the quality,
reputation.
measurement and test industry pro-
moting improvements in manufactur-
ing processes and products through Eliminating counterfeits 25
quality control and quality manage-
New pharmaceutical track and trace approach uses
ment - from shopfloor to line and
enterprise management. unique bottom marking to combat counterfeit drugs, an
increasing problem within national and international
Quality Manufacturing Todayis pub-
distribution systems.
lished by Cranbrook Media Ltd.
Registered company No. 06048241
Registered office: N.J. Ruse Associates, Game changer 28
Eagle House, Cranleigh Close,
Claiming to eclipses anything offered in the market-
Sanderstead, South Croydon,
CR2 9LH place, the new Focus3D is a high-performance, portable
Printers: Premier Press, Southend 3D laser scanner from Faro.
© Cranbrook Media Ltd.
Micro measurement for micro machining 30
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New advances in optical 3D metrology provide 6-7%
aanndd EEuurrooppee
improvements in process performances in micro machin-
RReeggiisstteerr oonnlliinnee aatt ing applications. By Brian Kyte and Mark Raleigh.
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Philips sees the light 33
Philips Lighting uses NDT X-ray and CT Radiography to
drive research, quality and productivity - plus reduce its
PPrroodduucctt aanndd ffeeaattuurree aarrttiiccllee ecological footprint.
eennqquuiirriieess
Log on to www.qmtmag.com for Force & torque 35
direct links to companies and
products featured in this issue. Shopfloor 36
Non-contact 37
CMMs 38
3
QMT November/December 10 www.qmtmag.com
p4,6,8 news.qxp 17/11/2010 12:53 Page 4
NNEEWWSS
Quality manager the door."
Editor’s comment
In August 2002, Ms. Eckard,
whistleblower wins
then a global quality assur-
Everybody’s get- ance manager with GSK, was
£61m payout
ting older sent to the Cidra factory to
lead a team of 100 scientists
A former quality control man-
Is it just me or is everybody and quality experts brought
ager at GlaxoSmithKline
getting older? Of course, as from around the globe to fix
(GSK) has received £61m,
each day passes, all who manufacturing violations
believed to be the largest ever
exist are one day older. But cited by the FDA of the USA.
reward for a whistleblower,
its not just a rhetorical ques- Cidra was then GSK's No. 1
after exposing a series of con-
tion. What I mean is that factory in the world, making
tamination problems at a
there seems to a definite over 20 products worth $5.5
drugs factory in Puerto Rico, people with the right combi-
aging of our industry. billion annually, including
and a subsequent cover-up by nation of skills. The result is
Looking around at an indus- blockbuster drugs Avandia,
company management. that one company’s recruit-
try gathering recently, there Paxil and Coreg.
GlaxoSmithKline (GSK) has ment success robs another of
were a lot of grey heads What she discovered went
agreed to pay the US govern- a valued, and difficult to
present, me included. far beyond the manufacturing
ment $750 million to settle replace, team member. The
People, mainly men, of mid- violations previously uncov-
civil and criminal charges that pool of available talent is
dle age and above predomi- ered by the FDA. The compa-
it manufactured and sold growing older and shrinking
nated. Is this a clue to what’s ny repeatedly ignored serious
adulterated drug products to as time passes. Clearly, more
happening in our industry? failings, including allegations
Medicaid and other govern- must be done by the industry
Are we recruiting enough that staff were "skimming"
ment health plans. The settle- itself if it is not to run into
young people into the world drugs to sell them on the Latin
ment was the result of a major problems in a few
of manufacturing and, in American black market and
whistleblower lawsuit filed in years time. But what initia-
particular, that of measure- that its factory had mixed drug
2004 by the law firm of tives should be made and
ment, test and inspection? types and doses in the same
Getnick& Getnick LLP on whose responsibility is it to
Anecdotal evidence suggest bottle. Over the next 10
behalf of Cheryl Eckard, a for- drive them? Yet again that
we are not. Speak to any months, she repeatedly alert-
mer quality assurance manag- apocalyptical quote from
company supplying prod- ed a string of GSK executives
er with GSK. "The success of Deming may spur action
ucts or services in these key to a catalogue of breaches,
this whistleblower lawsuit here, “Survival is not
areas and, typically, they only to be blocked and even-
will change the way that drug mandatory!”
will decry the skills shortage tually sacked in 2003.
companies run their facto- Brendan Coyne
- that it’s very difficult to find In a statement, the drugs
ries," said Neil Getnick, man- Editor QMT
group said: "We regret that we
aging partner of the Getnick
operated the Cidra facility in a
firm. "Now every employee
who works with manufactur- Cheryl Eckard to machine that management is putting manner that was inconsistent
ing issues -- from quality operators -- has a viable profits ahead of patient safety with current good manufac-
assurance executives like option if they have evidence by letting bad products out turing practice. GSK worked
hard to resolve fully the man-
NPL invests in one of the measurement of the major- Measurement. “In addition the
the most accurate ity of features on these taper software application deemed
CMMs in the world thread gauges. Engineers suitable for the task was
from the NPL and Hexagon QUINDOS, in particular the
The National Physical
Metrology’s Leitz factory in module for Screw Thread
Laboratory (NPL) is the UKs
Germany worked together to Inspection. The software,
National Measurement Institute
investigate how a Coordinate Hexagon Metrology’s applica-
well known for providing the
Measuring Machine (CMM) tions team, and trials on NPL’s
traceability against which every
could be utilised. Two key ele- existing Leitz PMM have proven
day metrology is based. One
ments were the need for a to us that this is the right solu-
of the tasks undertaken by NPL
highly accurate measurement tion.”
is the certification of Reference
facility and a software platform In addition, NPL is looking to
Master Gauges to American
competent of coping with the use the Leitz PMM-C Infinity as
Petroleum Institute (API)
necessary calculations. a platform for measuring arte-
Specifications, a role they
“The Leitz PMM-C Infinity facts such as ring gauges, plug
undertake on behalf of the
with a specified maximum per- gauges, end standards and
European Association of
missible error of 0.3 + L/1000 line standards in much the
National Metrology Institutes
was chosen as the CMM is same way as NPL’s existing
(EURAMET) for the whole of extremely time consuming and
capable of automatically Leitz PMM is used for the cali-
Europe. API gauges are com- labour intensive. In order to
measuring API gauges to the bration of step gauges.
monly used in the oil and gas reduce the time required for
measurement uncertainties www.leitz-metrology.com
industry. calibration NPL and Hexagon
required”, explains David
Until recently the process to Metrology undertook a project
Flack, NPL Engineering
certify API gauges has been to look at other methods for
4
www.qmtmag.com QMT November/December 10
Total quality
control solutions
where you need
us most –
everywhere!
Coordinate Measuring Machines Vision Measuring Machines
Form Measurement Optical Measurement Sensor Systems
Test Equipment and Hardness Testers Digital Scale and DRO Small Tool Instruments
Mitutoyo (UK) Ltd
West Point Business Park
Andover, Hampshire
SP10 3UX, United Kingdom
T [phone]
F [phone]
[email protected]
www.mitutoyo.co.uk
Software Support Services and Training
p4,6,8 news.qxp 17/11/2010 12:53 Page 6
NEWS
ufacturing issues at the Cidra tions submitted quantitative
EVENTS INNOVATION
facility prior to its closure in and qualitative information to
2009 ASTD about their learning
2010
and development practices Digital testing for new
Vision industry shows and programs. Applications
December 1 consumer products
strong indications of were assessed in a blind
FFrreeeeffoorrmm NNeettwwoorrkk:: NNoonn--
CCoonnttaacctt MMeeaassuurreemmeennttss,, GGooiinngg recovery review by members of the A unique test facility came
BEST Awards advisory com- online on October 11th, allow-
FFoorrwwaarrdd wwiitthh CCoonnffiiddeennccee
Coventry TechnoCentre, A number of recent indicators mittee, a select group of ing businesses to test new digi-
Coventry University Technology suggest that the vision indus- experts in the learning and tal services and run trials with
Park, Coventry UK try has weathered the worst of development field. consumers in a dedicated area
of the internet. IC tomorrow,
the global recession and is www.niit-tech.com
developed by the UK's
http://www.npl.co.uk/events/1- poised to emerge with posi- www.astd.org
Technology Strategy Board,
dec-2010-freeform-network tive signs of growth. Recently
enables content owners and
published surveys for 2010 Lean partnership with
application developers - any
from the European Machine Lloyds Register Quality business with a new service,
Vision Association (EMVA) Assurance (LRQA) new business model or new
2011 and the Automated Imaging way of deploying hardware or
Association (AIA) in the US Catalyst Consulting software technology - to trial
January 13 - 16 predict an 11 per cent (Catalyst), provider of Lean their ideas on British con-
**AAuuttoossppoorrtt IInntteerrnnaattiioonnaall 22001111 increase in turnover and a Six Sigma solutions is to part- sumers.
Initiated by the 2009 Digital
NEC, Birmingham, UK 2.6-4.6 per cent increase in ner with Lloyds Register
Britain report, which tasked the
www.autosportinternational.com sales respectively in their par- Quality Assurance (LRQA).
Technology Strategy Board to
ticular regions. Similarly, an LRQA will market and sell
establish next generation digi-
January 16-18 informal survey of UK Catalyst's Lean Six Sigma
tal test beds for new products
MMiiccrroonnaarrcc AAllppiinnee MMeeeettiinngg --
Industrial Vision Association Public Open courses and In-
and services, IC tomorrow
EEqquuiippmmeenntt ffoorr mmiiccrroopprroodduuccttss
(UKIVA) members attending Company training and sup- brings product and service
Villars-sur-Ollon, Switzerland
the UK’s Advanced port to their worldwide client developers and programmers
www.mam2011.org/
Manufacturing exhibition ear- base and LRQA's range of together with content providers
lier in 2010 revealed an management systems training and gives them access to real
February 16-17
**SSoouutthheerrnn MMaannuuffaaccttuurriinngg && upturn in enquiry levels and will now be available to users, all within a purpose-
EElleeccttrroonniiccss EExxhhiibbiittiioonn actual business since the Catalyst clients. built, experimental environ-
ment.
Farnborough, UK beginning of 2010. email: info@catalystconsult-
While IC tomorrow is a pur-
www.industrysouth.co.uk www.ukiva.org ing.co.uk
pose-built online testing
www.atalystconsulting.co.uk
ground where companies of all
March 30 -April 1 2010 ASTD ‘BEST’
sizes can trial their new prod-
**MMeettrroommeeeett:: IInntteerrnnaattiioonnaall
Awards rank NIIT ucts, it provides registered pub-
CCoonnffeerreennccee oonn IInndduussttrriiaall Hexagon finalizes
DDiimmeennssiioonn MMeettrroollooggyy Technologies among top lic users with the opportunity to
Intergraph acquisition try out applications and servic-
Bilbao, Spain 3 globally
es, giving potential consumers
www.metromeet.org
Hexagon AB has completed the opportunity to provide
April 5-7 The American Society for
their acquisition of Intergraph feedback and shape products
**AAeerroossppaaccee TTeessttiinngg Training and Development
Corporation. for a purchase before they go on sale.
Hamburg, Germany (ASTD) ranked NIIT
www.aerospacetesting.com price of $2,125M. Intergraph A wide range of content
Technologies Limited, an
is a global provider of enter- providers, such as Sony Music,
international IT solutions Getty Images and Crytek UK,
May 3 -6 prise engineering software
provider, third globally in the have already agreed to partici-
**CCoonnttrrooll 22001111 and geospatially powered
2010 ASTD ‘BEST’ Awards. pate in IC tomorrow and will
Stuttgart Exhibition Centre, solutions that enable cus-
The BEST Awards recognize make some of their content
Germany tomers to visualize and man-
www.schall.de organizations that demon- available, allowing product
age complex data
June 7-9 strate enterprise-wide success and service developers to con-
Intergraph is now a wholly- sider how they may build new
**SSuubbccoonn 22001111 through employee learning
owned subsidiary of Hexagon services and find innovative
NEC, Brimingham, UK and development. Thirty one
AB. Intergraph will continue new ways to use and commer-
www.subconshow.co.uk of the world’s best learning
to operate under the cialise the content.
organizations from across the
Intergraph name/branding The IC tomorrow platform is
world gathered at the recep-
and will become the core soft- a facility for the benefit of
tion held on 30th September British businesses and is open
*QQMMTTiiss aa mmeeddiiaa ppaarrttnner ware growth platform for the
2010 in Washington DC to to everyone.
Hexagon business.
receive the awards. www.ictomorrow.co.uk/home
Through its measurement
For the 2010 BEST Awards /provider
technology, Hexagon pro-
NIIT Technologies competed
duce a tremendous amount of
against 104 organizations in 9
data from various sensors.
countries. These organiza-
6
www.qmtmag.com QMT November/December 10
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New fi ve-axis head for touch trigger inspection gives up to
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For further information please visit www.renishaw.com/ph20
or call us on 01453 524111
Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire GL12 8JR United Kingdom
T [phone] F [phone] E [email protected]
www.renishaw.com
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p4,6,8 news.qxp 17/11/2010 12:53 Page 8
NEWS
Intergraph's software will act facturers (41%) think uncer- Most reliable cars and Lexus, remained among
as the "presentation layer" to tainty about demand will limit the most reliable and earned
survey - European
visualize this data to help cre- their investment plans over top scores in five vehicle cat-
ate actionable intelligence for the next 12 months. This is the makers momentum egories. Only the all-wheel-
both organizations' cus- lowest figure since January drive Lexus GS and the new
stalled
tomers. 2008 (41%) and compares Lexus IS 250 convertible are
www.hexagon.se with 54% for the previous below average. The
While Honda and Toyota still
www.intergraph.com quarter. redesigned 2010 Toyota
dominate in reliability, euro-
www.cbi.org.uk Prius, hurt by antilock brake
Strong UK manufactur- pean momentum has stalled, problems on early vehicles,
ing growth and exports Engineering award for according to the latest US scored only average. That is
Consumer Report whose
expected - CBI Renishaw’s chairman quite a drop from previous
findings are based on predict-
years..
The manufacturing sector Sir David McMurtry, (photo: ed ratings. Its Annual Auto Honda and Acura are
expects a solid rise in output right) chairman and chief Survey is derived from sub- among the top four brands,
over the next three months executive of global engineer- scribers' experiences with 1.3 with their models topping five
driven by predictions for a ing company Renishaw plc, million vehicles, but is not vehicle categories. Hyundai
stronger increase in export has been honoured with the based on road tests. and Kia continued to do well,
orders, the CBI said on prestigious General Pierre The 2010 report found that with only one model, the Kia
October 19th. The UK's lead- Nicolau Award by the while European reliability had Sedona minivan, rated below
ing business group said that International Academy for been improving, momentum average. All six new models
this follows an easing of pro- Production Engineering seems to have stalled. All for 2010 had average or better
duction growth in the past (CIRP). The award, which was Porsche and Volvo models reliability, an impressive first-
quarter. presented to Sir David at the are rated average or better. year showing.
Of the 420 manufacturers Academy’s annual assembly But Audi, BMW, and Nissan's mainstream mod-
that responded to the in Pisa, Italy during August, is Mercedes-Benz are among els did well. But the small
Quarterly Industrial Trends presented each year to indi- the worst automakers overall. Nissan Cube had a below
Survey, 32% expect a rise in viduals who have made sig- The Porsche Boxster has the average score in its first
output volumes, and 14% a nificant and distinguished best predicted reliability in appearance in our survey. The
fall, giving a balance of contributions within the field the survey, while the Audi A6 Infiniti models were all aver-
+18%. This follows a figure of of production engineering. 3.0T and Jaguar XF have the age or better.
+9% for the last three months. The presentation of the worst. Subaru had a good record
BMW had a bad year, with
This is primarily driven by overall, with a top rating
five of 11 models now scoring
expectations of a faster going to the four-cylinder
below average. Although the
increase in exports in the Legacy sedan and the non-
BMW M3 topped the sporty
coming quarter, with a bal- turbo version of the Forester
cars category, the 1, 3, and 5
ance of +15% expecting vol- SUV. The WRX was the only
Series models with the 3.0-
umes of export orders to rise. model that rated below aver-
litre, turbocharged engine had
Domestic order growth is age.
high problem rates related to
more subdued with a balance The survey found that while
the fuel system, among other
of +2% expecting an increase. some GM nameplates had
issues.
Employment and invest- been among the least reliable
Mercedes-Benz had the
ment trends in the manufac- brands in past years, they now
least reliable vehicles in three
turing sector are positive. rank above some major
categories. Six of its 13 mod-
Employment saw the greatest European competitors. But as
rise since January 1989 with a Nicolau Award, which hon- els were below average, and a company, GM is still far
balance of +6% of firms say- ours CIRP founder General the GLK SUV was far below from tops in reliability.
ing that they had taken on Pierre Nicolau, was made by average this year. The Ford continues to be the
new staff. its president, professor Gerry redesigned E350 sedan was most reliable American
In addition, investment Byrne, who said, “Sir David above average, but the new E- automaker. Ninety percent of
intentions for the coming year McMurtry has made very Class coupe, a wholly differ- Fords, including Lincoln mod-
have strengthened further. many significant contributions ent car, was a disappoint- els, have at least average reli-
Manufacturers said they plan to the field of metrology, a ment. ability.
to spend more on plant and subject that was of direct and Almost three-quarters of the Chrysler remains the low-
machinery over the year great interest to General Audi models analyzed were est-ranked manufacturer in
ahead: a balance of +10% Nicolau. He is named as an below average. Volkswagen the independent survey - with
said that they would increase inventor or co-inventor on did better, with its Golf (for- only one vehicle recommend-
capital expenditure in this some 47 Rolls Royce patents merly Rabbit) doing very well ed, the four wheel-drive
area, with investment plans at and on over 150 Renishaw and the various Jetta models Dodge Ram 1500.
their strongest since July 1997 inventions.” doing average or better. www.consumerreport.org
(+21%). www.renishaw.co.uk Despite recent safety
recalls, Toyota models,
Furthermore, fewer manu-
including those from Scion
8
www.qmtmag.com QMT November/December 10
The Offi cial
Business
Networking Event
for the Motorsport
Industry
International Motorsport Business Week Events for 2011 (10-16 Jan, 2011)
• RACETECH
World Motorsport Symposium
Forming part of an extended range of focused
business and network events, International • MIA Cleaner Racing Conference
• MIA Business Excellence Awards Dinner
Motorsport Business Week is an exciting trade

initiative that brings the UK’s motorsport • Autosport Engineering Show,
in association with Racecar Engineering
industry together; which includes symposiums,
conferences, seminars, an international
• International Business Exchange (IBE)
business exchange, and an industry awards
dinner all revolving around Europe’s largest
• Watkins Lecture
Motorsport Trade Show, Autosport International.
• Autosport International
13 - 16 January 2011 NEC Birmingham, UK
For more information & dates visit:
internationalmotorsportbusinessweek.com
13 - 16 January 2011 NEC Birmingham, UK
Supported by:
13 - 16 January 2011 NEC Birmingham, UK
13 - 16 January 2011 NEC Birmingham, UK
p10.11 PILATUS api.qxp 17/11/2010 12:57 Page 10
LASER TRACKERS
Stress-free quality
Portable laser-based measuring technology supports quality improvement and
production assembly at Swiss aircraft manufacturer, Pilatus Flugzeugwerke.
Pilatus Flugzeugwerke AG, founded in 1939, trol within production increases, as all of the parts
is the leading manufacturer of single-engine and the modules produced from them must under-
turboprop aircraft and the only Swiss com- go an entire and extremely precise quality control
pany to develop and construct aircraft and train- check. In particular, observing the accuracy of fit
ing systems and sell them on every continent. The within the current partial series manufacturing
highest demands in terms of quality apply global- plays a vital role within Pilatus. The customers'
ly within the aviation sector. A task that already individual challenging requests can only be taken
represents a challenge within series aircraft manu- into consideration and tested with this production
facturing becomes a work of art in itself within process.
customised aircraft manufacturing. As thousands From early in 2009, an API laser tracker has
of individual parts are involved that have to fit played a major part in the company’s ability to
together perfectly, the complexity of quality con- implement these customer requests. Pilatus manu-
factures the parts of an aircraft, such as the body,
cockpit or wings, at different sites. The measuring
points are already defined when they are con-
structed, enabling the jigs for the parts assembly to
be checked at a later stage. Measuring these
points guarantees that the jig corresponds with the
CAD data. On the basis of these reference points,
an aircraft wing, for example, which is made up of
thousands of individual parts, can be assembled
Jig for the cockpit precisely and be checked at crucial points to
construction. The ensure that it corresponds with the CAD data. The
measuring system laser tracker realises the measuring point devia-
in the foreground
tions from the CAD model in real time - a prereq-
10
www.qmtmag.com QMT November/December 10