Happy Holidays from FARO!

The FARO blog will return on January 5, 2010. Until then, have a great holiday and a safe and happy New Year!

Be sure to view our holiday card at www.faro.com/seasonsgreetings. This electronic card allowed us to take the money saved by not printing cards and donate it right back to our community, making sure that local children had a gift to open this year.

Robotic Drilling using Laser Tracker Technology

It seems that more manufacturing tasks today are being assisted by robots. Whether it’s out of convenience, safety, or cost, there’s no question that the technology keeps improving. But the one missing piece is that these robots are not yet “intelligent”. They need assistance from software and other hardware to make them accurate and repeatable.

Let’s explore an example of metrology hardware used along with robotic technology:

Variation Reduction Solutions, Inc. (VRSI) has been providing customers with state-of-the-art vision solutions for metrology, industrial robot guidance, and contract inspection services since 1998. The VRSI team consists of the most experienced vision, robot guidance, and metrology specialists in the world to provide customers with expert services and unbiased technology evaluations.

VRSI is the prime contractor on two ongoing SBIR programs administered by the Air Force Research Laboratory (AFRL) and recently completed a third, known as Inlet Duct Robotic Drilling (IDRD). IDRD is now moving to the production stage and involves metrology-guided robotic drilling on key components of military aircraft.

What was the challenge?
IDRD required VRSI and its partners to guide a robotic drilling system that drills and countersinks holes into a military aero structure. The traditional method of drilling these structures required operators to manually crawl into the duct with hand drills and templates. This process was slow, ergonomically challenging, and lacked in-process verification of hole accuracy.

What was the solution?
VRSI and its partners knew they could perform this job more quickly and efficiently using off-the-shelf robots with external guidance, and so they evaluated several technologies and decided on a Laser Tracker. The Laser Tracker is the ultimate solution for VRSI since it is small enough to fit in the duct, yet achieves extremely high accuracy.

How does it work?
The Laser Tracker is used to correct the drilling robot’s position to a radial tolerance of less than two thousandths of an inch. After the drilling sequence is completed, the Laser Tracker is again used to guide a robot mounted inspection device to the proper location to inspect the drilled and countersunk holes. The Laser Tracker’s attributes – size, portability, stability, repeatability, traceability, and accuracy – are benefits that VRSI has seen over traditional methods. Leveraging the efficiency of the latest off-line robot programming methods, the Laser Tracker is used to guide the drilling of over 5,000 holes in the operation.

What was the result?
“A single automated cell replaces several individual, manual cells, and reduces the time to build from weeks to days. We can safely speculate that we are saving millions of dollars over the course of the program with IDRD.” – Don Manfredi, Chief Operating Officer, VRSI

3D Scanning in Forensics

If you’ve ever recently watched an episode of CSI or any other investigation drama on television, you may have seen some interesting technology. No, I’m not talking about infrared scopes or microscopic DNA testing. I’m referring to 3D scanning technology.

In the past few of years more and more crime scenes are being documented by 3D laser scanners. In the field these devices have proven there invaluable worth for the accurate and efficient capturing of data. The older method of using total stations isn’t able to capture as many measurements in the same amount of time as a 3D scanner is able to. Hundreds of thousands of points can be scanned in a matter of minutes compared to only a few points being captured in the same amount of time by a total station. The better quality of evidence usually leads to an increased chance of solving the crime.

Depending on the crime scene will determine what type of 3D laser scanner to use. For example, the FARO Laser Scanner Photon is ideal for environments containing evidence in a 30-120 meter range. The level of detail captured along with the speediness at which it scans provides investigators a virtual photograph in millions of points. Using a forensic software package, technicians can then analyze the scene just as it appeared at the time of the crime.

To read the entire article on 3D Scanning in Forensics, click HERE.

GM to Invest Millions in Michigan Facilities

On Monday, General Motors (GM) said that it will spend $700 million at eight different Michigan facilities with the goal of getting its new rechargeable electric car, the Chevrolet Volt, road-ready. Obviously, this is a technological and economic boost for the state of Michigan and, as we’ve seen, what happens in Michigan affects what happens in other states. A rebounding economy in Michigan can clearly lead to a rebounding economy in nearby states and everywhere else.

These investments by GM will come in the form of new machinery and equipment. GM realizes that improvements in their facilities and processes, in their own infrastructure, will lead to better products and profits. Making a better product – one your customers want, with the quality they expect – is crucial and doing so at a minimum of effort and cost just makes sense. GM is like any other business – one that has struggled or not – they need to make the best possible products and offer the best quality for the best price. Improving their facilities and machinery and getting them up-to-date with the best technology available today is the way to stay, or to become, competitive.

Much of the investments and future plans are efforts to spend more money on products to get them to market faster. A faster design, implementation, and production cycle equals a faster return on investment. This is the model that every successful business must follow and manufacturers are no different. If anything, this model applies to them even more so.

Read the full article in the Chicago Tribune
Watch a recorded webinar on improving manufacturing efficiencies

US Manufacturing Maintains a Global Edge

After one of the toughest years for the manufacturing industry, let alone the US economy as a whole, a recent Manufacturers Alliance/MAPI report predicts that manufacturing production will begin to recover "to 5 percent growth in 2010 and 6 percent growth in 2011." Other analysts, too, are seeing a brighter future for manufacturing in the coming years. In an interview with Dr. Chris Kuehl, Economic Analyst, Fabricators & Manufacturers Association, Manufacturing.net learned that Dr. Kuehl sees certain advantages that the US has over other countries.

Dr. Kuehl says there are "three things that give US manufacturers a bit of an edge even with China in the picture." The first of which being the weak value of the dollar. "With the dollar down at the level it currently is, we're essentially discounting anything we sell internationally. But at some point, that advantage begins to go away." The second factor Dr. Kuehl recognizes is that China, while they hold a large portion of our debt and have fewer regulations posed on their manufacturers, is still relatively rudimentary in their manufacturing culture. "They do have a few sophisticated sectors, but China's specialty is the labor-intensive, mass-production items for WalMart. The US continues to be a more high-value manufacturer." Finally, Dr. Kuehl points out that our single biggest advantage is that US manufacturers are closer to their markets. "Being closer hasn't been a huge issue in the last 10 or 15 years, but if you track what is happening with the energy crisis, it becomes more expensive to bring things from various distant and drawn out supply chains. So you began to see, particularly if oil prices come back up, more incentive to produce closer to the consumer. You now have much more customized, specialized manufacturing and smaller lots."

Dr. Kuehl certainly recognizes the challenges we still face, such as training, hiring and maintaining the export sector, but overall if we play our cards right and focus on the strengths we have that give us the advantage over other countries - we have a chance to turn this around and make the recovery that, for example, MAPI expects.

Read the full interview with Dr. Chris Kuehl
For additional information about MAPI, click here.

Improving Manufacturing Efficiencies Using Portable Metrology

More and more, there is a need to improve manufacturing processes in order to better product quality, lower costs, and increase profitability. Metrology, when both accurate and easy-to-use, is instrumental in the design, manufacturing, and assembly of parts and products. An increasing number of manufacturers require more and more high-precision measurements for their products – each with various complexities, sizes, and shapes. The best possible metrology solution can help guarantee the precision and quality of this ever widening range of products and their production processes.

In the past, traditional measurement tools such as calipers and micrometers were sufficient. That was the best technology available and that was the standard, despite inherent difficulties with complex parts, measurement uncertainty, and a lack of CAD capability. Then fixed coordinate measuring machines (CMMs) came into prominence. The CMM provided very high levels of accuracy, could be automated, and allowed CAD comparisons. But the fixed CMM took away the advantage of portability the older hand tools provided – parts had to be taken to the CMM, to a specialized temperature-controlled room away from the production floor. Not only was this inconvenient, it was costly and inefficient.

As a solution to these problems, portable CMMs were developed. They provide both the flexibility and portability of hand tools and the accuracy and CAD capability of fixed CMMs. There are several types of portable CMMs: articulated measurement arms, laser trackers, and 3D laser scanners. Each provides the benefits of fixed CMMs, but with the added flexibility of being portable. They don’t require a dedicated measurement room, are lightweight, and can easily go to the part that needs measurement. Not only do they perform like a fixed CMM, they are also typically much less expensive.

Unlike their older brothers, portable CMMs can be used throughout the manufacturing process. They can improve quality straight from incoming inspection on through to final inspections before shipping. Portable CMMs are perfect for dimensional inspections and analysis, for machine alignments, for in process and on-machine inspection, first article inspection, CAD-to-part inspections, reverse engineering or rapid prototyping, and even for work in existing measurement rooms.

To remain, or to even become, competitive today, manufacturers need to utilize the best metrology technology available. Time is money and portable metrology can boost efficiency by providing the ability to accomplish jobs with the minimum expenditure of time and effort.

Register to attend a free webinar on how portable CMMs improve efficiency.

Laser Trackers: Defining Accuracy (Part 3, Final)

Up to this point, we have defined the term “accuracy” in how it relates to laser tracker measurement systems.

We reviewed angular versus distance accuracy, as well as volumetric accuracy.

In this final section, we will continue our discussion on volumetric accuracy, as well as cover some consequences of sub-optimal angular accuracy.

In order to illustrate how much angular errors dominate for a measured object, consider Figures 1 and 2.









Figure 1 – Points on measured object in line with the laser tracker














Figure 2 – Line between two points on the object perpendicular to the laser tracker

If the laser tracker in Figures 1 and 2 is deemed to be 2 meters from the measured object, the following typical MPE performance is attained from a measurement of the 2.3 meter length.

Assume use of IFM and a Typical MPE
Figure 1 = 3 micrometers
Figure 2 = 33 micrometers

Note the relatively large difference - this is because in Figure 2 the laser tracker’s relative position to the points which require to be measured dictate that the angular or transverse measurement system errors dominate.

Objects with features which require measurement are rarely offered up as depicted in Figure 1. Objects tend to be more irregular in shape and size, and very often not all points can be viewed from an in-line position. Typical examples might be large assembly tools for the aerospace industry.

Figure 2 orientation is more common with the scenario mentioned previously (in Part 2 of our discussion) coming into play if not all points can be seen from one position. The moment that multiple laser tracker positions come into play coupled with objects positioned to the laser tracker as depicted in Figure 2, means that the angular measurement system errors dominate.

It can therefore be concluded that the specifications and actual performance of the angular or transverse measurement systems onboard the typical laser tracker play a very important role in its day-to-day performance for the average user. It’s very easy to forget this fact when confronted with the specifications and by the outstanding performance of modern IFM and ADM distance measurement systems.

Selected Consequences of Sub-Optimal Angular Accuracy
Examples of sub-optimal angular accuracy are apparent for large assembly tooling within the aerospace industry. If angular accuracy is sub-optimal, the following could ensue:
• Poor initial reference system leading to a lack of accuracy and repeatability when setting and certifying the tool
• Poorly fitting parts leading to cost issues downstream of the assembly process
• Costly rework based on a poor signal from the measurement system (costs include labor and time tying up a tool which is on critical path)

If the angular accuracy is optimized, it is more likely that the tool will not have to be reworked during its first recertification due to measurement variation at least. Reworking tools such as these described can cost several thousand dollars.

Conclusion
Understanding accuracy terms is an important aspect of selecting the best instrument for a particular application. In the case of laser trackers, distance accuracy specifications are often not achievable in the end user’s application due to the limited measurement conditions that would be required. The majority of the time the laser tracker user is most interested in measuring points and dimensions that require movement of the encoders and place the application into the volumetric accuracy case. Thus it is the volumetric performance of the instrument that is most critical when considering a laser tracker for the majority of applications.


Click here to read the complete white paper

Laser Scanning Production Floors

With lean manufacturing being such a focus in today’s world economy, it wasn’t surprising to learn that American automakers are leading the way in redesigning assembly processes. One particular company decided to implement virtual manufacturing many years ago to streamline product development. Ford Motors adopted the philosophy of simultaneous engineering. This term refers to using 3D scanned data to conduct simulations of production processes. In order to accomplish this task, the FARO Laser Scanner Photon was brought in to provide point cloud data of the production floor. The FARO Photon has a color capability that makes point measurement easier to the human eye. After several scans, the 3D meshes were then mixed with CAD models to create simulations that allowed Ford Motors to review for production enhancements.

Click Here for the complete story in laser scanning production floors.

Laser Trackers: Defining Accuracy (Part 2)

Distance Measurement (Ranging) Accuracy

As mentioned previously, the distance measurement systems typically found in a laser tracker are an IFM and ADM or even ADM only. Independent upon whether IFM or ADM systems are being used, the ability of these systems to detect and measure displacement is well known and documented.

Interferometers were typically used to measure the displacement between two points and therefore the product would be a distance between the two points. It follows that in order for a laser tracker instrument to measure distance optimally, it needs to be positioned in line with the points to be measured. In this case there is no influence from the angle measurement system.

Angular (Transverse) Measurement Accuracy
The angular accuracy of a laser tracker describes how well the instrument discerns angle measurements from its angular measurement encoders prior to processing them together with the distance or ranging element in the form of a coordinate.

Angular Measurement Accuracy versus Distance
With some laser trackers specified out at ranges of 50 meters or more, the pure ability for the unit to accurately measure angles is very important for respectable performance in the field. This becomes more or less important depending upon the volume of the object and where it is practical and economical to position the instrument in order to measure the points of interest.

Volumetric Accuracy
Volumetric accuracy is often used as a term to describe how accurate the instrument is for a particular measured volume. Where they exist, illustrated concepts of volumetric accuracy from manufacturers have to be aligned with the ability of the user to practically position the instrument in the real-life situation for their particular measured object.

Where measurement volumes are large it is sometimes more efficient for the user to reposition the instrument in strategic and practical positions to enable the viewing of all the required points of interest. The use of more instrument stations will have the effect of reducing the distance from the instrument to the points of interest which will also tend to weight the contribution of the angle measurement. This is especially true if there are practical limitations for the positioning of the instrument, placing more emphasis on the angular measurement capability in the quest to achieve an accurate set of coordinates.

In this scenario the following is relevant:
• The laser trackers have limited room to maneuver in the Z direction
• All points of interest cannot be seen from a single position
• Multiple laser tracker positions are required to achieve the required accuracy
• The highest possible accuracy is required
• The measurement volume dictates that the laser tracker angle measurement capability is exercised, especially in the Y (vertical) direction
• Measurement distances have been cut, but laser tracker angles are exercised more severely

To be continued…

What, Exactly, is Portable CMM Technology?

Metrology technology has constantly evolved as the needs of manufacturing have become more stringent. Recent developments have allowed portable CMMs to become more prominent in the marketplace since they can be integrated into the manufacturing process. This has turned what has traditionally been an inspection device into a value added option for cutting-edge manufacturers.

There are several different tools available for the measurement and inspection of parts and products. The specific application often determines the best choice as each tool has its own benefits and drawbacks. Over the years, these tools have become more advanced in order to keep up with improved quality standards.

Today’s manufacturing demands often require that processes adhere to the best possible practices to maximize value. One clear way to do this is to improve production times and to minimize waste. Implementing portable CMM technology at every aspect of the manufacturing cycle can achieve this goal – improving both time and cost savings.

There are two main types of portable CMMs: articulated arms and laser trackers. Articulated arms determine and record the location of a probe in 3D space and report the results through software. To calculate this location, the rotational angle of each joint and the length of each segment in the arm must be know. The rotational angle is determined using optical rotary encoders that count rotations incrementally, and software is used to convert those counts into angle changes.

Laser trackers operate by measuring two angles and a distance. The tracker sends a laser beam to a retroreflective target held against the object being measured. As light is reflected off the target, it bounced back and re-enters the tracker at the same position it left and is measured by a distance meter, measuring the distance between the tracker and target.

Portable CMM technology can be used for many different applications and continue to grow in popularity. Companies implementing this technology are getting the accuracy results they need in addition to flexibility to use the unit wherever and whenever it's most convenient.

Watch a webinar on portable CMM technology.
Download a white paper on portable CMMs.

Ultra Machine Saves Money and Lives

As we celebrate Veterans Day, it’s also important to remember that there are many companies that provide high quality material for the military that helps protect our soldiers. One such company is Ultra Machine & Fabrication in Shelby, North Carolina. With over 20 years of fabrication and machining experience, Ultra Machine has earned a reputation for quality and expertise. They are proud to provide precision armor parts and weldments for military vehicles such as the Mine Resistant Ambush Protected (MRAP) vehicle.

In fact, most of the parts Ultra checks are machine and fabricated parts for the military. Older tools like gauges and calipers lacked several functional capabilities – GD&T, angles, parallel, and flatness, for example. Ultra was often left second guessing themselves on these 3D measurements and they also lacked a needed reverse engineering ability.
To solve these issues, Ultra turned to the FaroArm® – a precision instrument capable of providing accurate measurements of 3D features that quickly confirms parts are meeting or exceeding expectations. The deciding factor in their decision though was the FaroArm’s accuracy of up to .001” on an 8-foot Platinum.

Ultra now has several FaroArms that enable them to measure and document parts. They can view highly accurate, 3D product files in real time and provide statistical data to their suppliers and customers – an added benefit that helps Ultra remain a world-class provided of fabricated armor parts.

By using their FaroArms, Ultra has reduced scrap by tens of thousands of dollars monthly. “Just one mistake can cost us $10,000 fast,” said Quality Director James Shelf. “With FARO, we can prevent that mistake before it happens.”

Join FARO in honoring all of our military veterans – not only today, but everyday. And we’d also like to say thank you to people like those at Ultra Machine that help keep our veterans safe.

Read the full story

Researching Accident Investigations Using Laser Scanning Technology

FARO’s Laser Scanner Photon has proven to be a critical technological solution to the world of accident investigations. It is an industry that depends on the ability to make present observations from events that happened in the past. So much time and money is being tied up in court cases, therefore, forensic engineers look to laser scanning for dependable data that can provide them with tangible evidence.

Recently, Spar Point Research LLC posted an article which discusses how three companies use FARO Laser Scanners in their daily forensic operation. Each company describes how 3D scanning has revolutionized their surveying and applied measurement techniques. Packer Engineering, Arnold & O’Sheridan, and Gilbert Engineering are all experts in the accident reconstruction industry. They all have a unique story in how laser scanning has provided speed, safety, accuracy and portability.

For the full story in laser scanning for accident investigations CLICK HERE.

Laser Trackers: Defining Accuracy (Part 1)

Measurement instruments and systems evolve constantly, enabling the user to take advantage of a whole host of features. The technical specifications of most measurement systems may include reference to such entities as resolution and repeatability but will always include reference to the term accuracy.

Let’s explore the meaning of accuracy in the context of metrology in general and in particular for the use of a laser tracker instrument.

We’ll also explain the term and distinguish between in-line (or radial accuracy) and angular accuracy. Also described is the tendency for the angular errors to dominate during the measurement of a typical object and examples are offered to illustrate this.

Finally, we’ll illustrate the consequences of poor angular accuracy in particular.


Accuracy

Accuracy, or bias as it is sometimes called, is a term which can be described as the closeness of the agreement between the result of a measurement and a true value of the particular quantity being measured. In reality, we will never know the true value of the measured quantity which is why in cases where more certainty of the measured quantity is important, there tends to be an emphasis on ensuring that at least the accuracy of the measurement instrument is optimized.


Laser Tracking Instruments and Accuracy

Laser tracking measurement instruments are very versatile by nature, although their use is frequently for applications where there is a demand for the highest possible performance from the measurement system to characterize the object being measured.

One of the reasons why laser trackers have evolved into this high accuracy sector is because of their outstanding ability to accurately measure distances. This was initially due to the use of laser interferometers (IFM) followed later by Absolute Distance Meters (ADM).

Distance measurement capability on its own is not enough if a set of coordinates is required. In order to achieve this, the laser tracker instrument in its basic form is equipped with an angular measurement system to enable the distance measurement to be processed alongside two measured angles to arrive at the required coordinates.

It is clear then that in order for the ever-increasing customer specifications to be met, there has to be an emphasis upon the accuracy of both the distance and angular measurements of the instrument.


Specifications for Distance and Angular Measurement Accuracy

Dependent upon the manufacturer of the laser tracker, specifications over the last few years have varied in the sense of their presentation, usefulness and practicality to the user.

The introduction of the ASME B89.4.19-2006 standard has helped manufacturers to standardize the approach toward specifying, although there is some way to go in order that complete agreement is reached across continents.

The ASME standard offers the concept of Maximum Permissible Error (MPE) to the manufacturer and subsequently the user. MPE is useful in the sense that it encompasses the extreme values of error that are permitted by a specification.

The following is a typical distance measurement specification offered by a manufacturer. Please note that actual numbers are for reference only:

For the IFM system:
4 micrometers + 0.8 micrometers/meter

For the ADM system:
20 micrometers + 0.8 micrometers/meter

For the Angular or more often called the Transverse system
36 micrometers + 0.6 micrometers/meter

Note that in all cases there are two terms - the first term is the offset, while the second term is the slope or scale factor. The slope or scale factor is predominantly a function of distance; therefore it should encapsulate the range of specified environmental conditions together with the specified range of the instrument.

The MPE specifications can sometimes be offered as “Typical”, in which case they constitute a halving of the full MPE value for the purposes of portraying a value which will be typically achieved the majority of the time.

As for the relevance of the MPE specs to the user, it’s clear that the declared MPE values can be compared to assess the relevance of the purchase across manufacturers. If Point-to-Point accuracy is of interest to the user, some manufacturers publish the formulae used to calculate the MPE, making it possible for the user to calculate his or her own situation.

Some manufacturers also offer to certify the instrument with respect to the B89.4.19-2006 standard. If this is available, together with processes to protect or guard-band the MPE specifications, it can only be of benefit to the user.

Download the full white paper.

GSA Support Provides a Bright Future for Laser Scanning

A recent announcement stated that two more companies have been awarded GSA contracts, specifically Building Information Modeling & Laser Scanning contracts. Kristine Fallon Associates Inc. was awarded five year contract for BIM while Quantapoint was awarded a five year $30 million for their nationwide scanning services which includes BIM, building modifications and performance upgrades. With over 1,400 laser scanning projects over the past 18 years, Quantapoint relies heavily on portable and accurate laser scanning equipment. FARO is proud to be their supplier of the Laser Scanner Photon 120. With up to 976,000 measurement points per second, the Photon is perfect for areas such as historic restoration, refineries, power plants and off-shore platform facilities.

To see that the future of BIM is getting full GSA support is an encouraging sign for the laser scanning sector. With more and more companies adopting the process of managing building data, laser scanning is becoming an integral part of construction industry. TO see the full announcement of the GSA contracts follow the link below:

http://www.sparllc.rsvp1.com/archiveviewer.php?vol=07&num=19&file=vol07no19-02

Optimism Returns to Manufacturing

A growing sense of optimism is returning to the manufacturing sector. According to the fourth Prime Advantage Group Outlook survey, this optimism is the result of improved revenues, customer demand, and hiring expectations. The “GO” survey seeks to determine the top economic concerns of midsized industrial manufacturers.

Among the highlights of the survey findings was that 80% of respondents expected revenue to stay the same or increase in the second half of 2009. This is a dramatic turnaround from the February GO survey, in which only 38% predicted revenue to stay the same or increase over 2008 numbers. Additionally, just 31% said that capital spending would likely decrease from the first half of 2009, whereas 66% indicated in February that capital spending would decrease from 2008 levels.

“The results of the latest Group Outlook survey show that small and midsized industrial manufacturers, across many sectors, are seeing new orders materialize,” says Louise O’Sullivan, president and founder of Prime Advantage. “These results indicate that the recovery is starting to gain traction across a broad spectrum of our economy.”
With several other survey results such as various cost pressures, purchasing, sourcing, and plans for the future, this article provides a keen insight into how manufacturers assess both the current situation and the prospects going forward.

Read the full article in Quality Magazine
Learn more about how to maximize returns in the recovery

CNC Machines: Performing Alignments and Volumetric Compensation

CNC (Computer Numerical Control) machines have successfully transformed the manufacturing industry from using hard-wired machines, whose operating parameters could not be changed, to machines that can cut curves as easily as straight lines and can produce complex 3D structures with ease.

Thermwood Corporation is currently the oldest CNC router company and continues to offer products for the woodworking, plastics, and aerospace industries.

An important process for their CNC machines is axis alignment verification. Their tools, however, were very time-consuming and just weren’t providing the desired solution. They also wanted a solution to performing volumetric axis compensation.

The FARO Laser Tracker became that solution for Thermwood. The amount of time required for machine alignments has been cut to less than half. What once took up to eight hours to complete can now be accomplished in approximately three. In addition, they can now perform volumetric compensation, which would not have been possible without the Laser Tracker.


Axis Alignment Verification

How it’s done:
• Initial Laser Tracker measurement setup is performed in the early stages of machine assembly
• SMR (spherically mounted retroreflector) is fitted onto a special fixture, which allows it to be attached to each rail and moved manually along them
• Fixture is then fitted with precision rail bearings, which allows it to track the rail very precisely
• Machine assembly is completed
• Servo drive system is fitted
• Computer control is installed
• Machine is again checked using the Laser Tracker
• Additional minor calibration adjustments are performed if necessary


Volumetric Compensation

How it’s done:
• Positioning data is acquired in a matrix pattern on multiple planes
• The entire work envelope of the machine is mapped
• A correction table is developed by
-Triangulating between the various points in volumetric model space
-Measuring the error for each position
-Formulating a table of correction data to be loaded into the machine control and accessed during program execution
• Method of compensating for error during the program cycle is essentially the same as with linear compensation, except during program execution the control is required to
-Simultaneously track and compare axis movement on three distinct orthogonal paths
-Affect positional corrections correspondingly on all three axes, in phase with program execution

Read the full story

The Future of Manufacturing

So it seems as though things may actually be turning around and getting better. Slowly. Not to get ahead of ourselves, but with the recent close of the third quarter of 2009, there seems to be more and more positive news stories about the increase of business in the manufacturing industry.

For example, there was a story this week in the Charleston Regional Business Journal that stated the "Southern region sales of metal cutting and metal forming equipment rose in August to $23.59 million, 8.1% higher than July's $21.82 million." Again, let's not get ahead of ourselves - year over year the industry is still down almost 70%, but the point is that this is not the only story of Q3 increases.

In the November 2009 issue of Money magazine, "Mechanical Engineer" was ranked #38 on the list of best jobs in America. Bloomberg.com reported this morning that the New York Empire Factory Index surged to a 5-Year high, up 15.7 points since September, marking "the first time the measure has shown expansion for at least three months since a period ending in January 2008."

While it is clear that this recovery won't be overnight, you can definitely start to see a steady amount of positive stories coming to light.

Read the full articles:

Manufacturing technology equipment sales up across Southeastern United States (Charleston Regional Business Journal)

Best Jobs in America (Money Magazine)

New York Empire Factory Index Surges to 5-Year High (Bloomberg.com)

The Fastest Payback on a Major Purchase in 37 years

Art Morrison has been building frames and suspensions for the drag racing and street market for over 37 years. His company, Art Morrison Enterprises of Tacoma, Washington, was honored by the Hot Rod Industry Alliance of SEMA with the 2007 Business of the Year award for its contributions to the industry.

AME reverse engineers and builds custom car chassis and suspension components. These can be 150-in long, sometimes well over 200-in. To measure these components, they used a variety of hand tools such as calipers, plumb bobs, and even measuring tape and paper. Using these traditional tools, it took up to 70 hours to fully dimension a chassis and even then it was often wrong had to be redone.

Then a customer asked Art if he had heard of FARO's portable CMM, the FaroArm®. He hadn’t, but within a week he had learned enough. “We went from no knowledge of the FaroArm to purchasing one in less than a week,” he said.
The FaroArm allows AME to do far more accurate drawings and translate those into very accurate finished products. They can now do even the most complex parts and get great results – the first time. Frame jobs that used to take up to 70 hours and still have mistakes can now be done right in just eight. Hundreds of man-hours have been saved using the FaroArm. Time savings is money savings and AME has done both.

“This is one of the few pieces of equipment that I have purchased that you can see the results from the first day, and it just gets better,” said Mr. Morrison. “For a major purchase, it will have a faster payback than anything I’ve bought in the 37 years that I’ve been in business.”

Read the full story

Gain More Favorable 3D Data from Your Scanning Process

The FARO Laser Scanner Photon provides high speed survey and documentation of any environment. It generates full detailed three dimensional replicas of complex environments and geometries in a matter of minutes. The resulting image is one with millions of 3D measurement points per scan. The Photon is capable of scanning at 976,000 points-per-second with a maximum reach of 120m, making it an ideal tool for documenting any world in three dimensions. Applications such as engineering, procurement, construction, heritage and even accident investigation require accurate and precise data generated from laser scanning.

In Quality Digest an interesting article called “The Quality Cycle in a Precision 3D Scanning Process” describes how to gain more favorable 3D data out of your scanning process.

As the advancement in laser scanning technology continues to improve, it’s no wonder that the data results stemming from this process must meet high expectations. While laser scanning provides detailed information for reverse engineering, critics will argue that it is too incomplete. This article discusses that it’s not the technology that lacks perfect results but the common practices for setting up a successful scanned project. This preparation is referred to as the Shewhart Cycle.

Learn more about the Shewhart Cycle.
Learn more about the Laser Scanner Photon.

Quality Improvements for Waterjet Cutting Machines

The science behind waterjet cutting has been around since the 1950s. However, it wasn’t until the 1980s that waterjet cutting systems became commonly used for cutting high-strength materials. The process is actually quite simple – water flows from a pump, through plumbing, and out through a cutting head. It is commonly used to fabricate and manufacture parts for machinery and other devices. As one of the fastest growing machine tool industries, waterjet cutting has proven to save time and money in countless applications.

WARDJet, Inc., located in Tallmadge, Ohio, is a manufacturer of waterjet cutting machines. WARDJet provides their customers with leading edge equipment and support for anything related to waterjet cutting.

WARDJet had always ensured the linear accuracy of its waterjet cutting machines with laser interferometer readings and circularity with ball bar reports. However, they determined that they wanted to measure 3-D volumes with their new 5-axis machine and in their future product designs.

They realized that their current ability to innovate, measure, quantify, and advance using their existing tools had reached a ceiling. With their desire for constant improvement, they decided to look for an alternative.

“If you can measure it, you can improve it” is a philosophy WARDJet turned to in its decision to invest in the FARO Laser Tracker. This extremely accurate, portable coordinate measuring machine is opening doors that were simply not there without it.

The FARO Laser Tracker takes verification and quantification of all the static and dynamic variables of building a waterjet to the next level – volumetric mapping. Volumetric mapping measures the location of the cutting head in three dimensional space, which is different from the actual mapping of the X, XX, and Y axes, which requires interpolation to determine the position of the cutting head and is done in only two dimensions.

Volumetric mapping is especially important when it comes to the 5-axis cutting head. WARDJet is now able to quantify accuracy in all five axes (X, Y, Z, A, and B) while the system is in motion and is actually cutting.

The FARO Tracker also allows them to see a complete representation of a machine. Previously, they had to piece together data shots that didn’t always explain what was being seen. Now they not only take static measurements, but they can also take dynamic readings and compare them.

“With the use of the FARO Laser Tracker, we have been able to verify and analyze parts of our machine that we previously couldn’t,” said Dave Papania, Engineer at WARDJet. “It has taken our calibration, quality, and R&D to a whole new level.”

Using their previous methods, laser calibration of their waterjet machines would take up to three hours. With the FARO Laser Tracker, they can now do the same work in close to one hour.

The investment in tools like the FARO Laser Tracker has made WARDJet more efficient in production by gathering infinitely more data in a shorter period of time. The ultimate result has been a higher accuracy waterjet cutting machine with improved reliability.

“Everyone is amazed at the power and capability of the FARO Laser Tracker,” said Papania. “It is extremely versatile, allowing you to measure in many different scenarios that were previously unobtainable.”

Did You Know?

Peking Ape Man Ruins is one of the most world famous palaeohuman ruins which is located on Longgu Mountain of Zhoukoudian in China. This cave was first excavated in 1921 and has since been the focus of being the historic site of the Ape Cave Man. It also contains the richest materials among the contemporary palaeohuman ruins. In 1961, the Ruins was approved by State Council as one of the first lot of sites under major historical and cultural site protection. With such restrictions scientists have limited access to the cave.

So how do scientists document data without disturbing the preservation of the cave? Unlike the first excavation, experts now have access to 3D technology which produces 3D images of the entire cave layout. The FARO Laser Scanner Photon uses laser technology to create a virtual environment scan of the cave. Scientists then analyze the data and compare changes in the geological formations without disturbing the integrity of the inner cave. 3D scanning is once again improving the way research can be documented and analyzed while have little to no impact on the natural surroundings.

Laser Trackers – IFM vs ADM Technology

There is a lot of talk today about the different types of technology used in laser trackers to determine the distance measurement. Let’s briefly discuss the two main technologies and how they work.

Distance measurement, an important function of a laser tracker, can be either incremental or absolute. Incremental distance measurement is made with an interferometer (IFM) and a frequency-stabilized, helium-neon laser. The laser light splits into two beams. One travels directly into the interferometer. The other beam travels out of the laser tracker, reflects off the spherically mounted retroreflector (SMR) and, on the return path, passes into the interferometer. Inside the interferometer, the two beams of light interfere, resulting in a cyclic change each time the SMR moves closer to or farther from the laser tracker by a distance equal to one quarter of the light’s wavelength (~0.0158 micron). Electronic circuitry counts the cyclic changes (known as “fringe counts”) to determine the distance traveled.

In a typical measurement sequence, the operator places the SMR in the laser tracker’s home position and resets the interferometer to the known (home) distance. As the operator moves the SMR to the desired location, the laser tracks along, remaining fixed to the center of the SMR. This procedure works well as long as the beam from the laser tracker to the SMR isn’t broken by an obstruction in the beam path. If the beam is broken, however, the number of counts is no longer valid and the distance isn’t known. When this happens, the laser tracker signals that an error has occurred. The operator must then return the SMR to a reference point, such as the laser tracker’s home position.

Interferometer-based measurement can trace its origins to the late 1800s – it was not until the invention of Absolute Distance Meter (ADM) that the laser tracker made its move from a laboratory instrument to a real-world measurement system. ADM represents the latest in laser tracker technology.

Absolute distance measurement capability has been around for a long time. Within the last several years, however, ADM systems have undergone dramatic improvement, offering accuracy comparable to interferometers. The advantage of ADM measurement over incremental distance measurement is the ability simply to point the beam at the target and shoot. The ADM system measures the distance to the target automatically, even if the beam has previously been broken. In a laser tracker with ADM, infrared light from a semiconductor laser reflects off the SMR and re-enters the laser tracker, where it’s converted into an electrical signal. Electronic circuitry analyzes the signal to determine its time of flight, multiplying this value by the speed of light in air to determine the distance from the laser tracker to the SMR.

Absolute distance meters first appeared in laser trackers in the mid-1990s. At that time, ADM units measured too slowly to permit scanning of surfaces. Because of this, all early laser trackers contained either an interferometer alone or an interferometer and an ADM. Today some absolute distance meters have been made fast enough to permit high speed scanning without negligible loss in accuracy. Hence some modern laser trackers contain only an ADM with no interferometer.

An example of this is the latest laser tracker from FARO, called the FARO Laser Tracker ION™. It contains the fastest, most sophisticated distance measuring system: Agile Absolute Distance Meter (aADM). This patented technology provides the ability to acquire a handheld target even if the target is moving.

The ION’s Agile ADM measuring system is the only ADM system on the market that is fast enough to allow for high density scanning without relying on an interferometer. Agile ADM modulates its laser beam at three slightly different frequencies. By comparing the phase of the three modulated frequencies received by the Laser Tracker, aADM eliminates any ambiguity and calculates the position of the target.

With Agile ADM comes great simplification of the system – there is no need to switch between ADM and IFM-based systems – aADM does it all.

Learn more about the FARO Laser Tracker ION

Documenting a Crime Scene

Conventional forensic surveys of crime or accident scenes — known as “total station work” — involve photographing the scene from numerous angles with a standard camera, tape measuring distances between critical objects, and diagramming relative positions of pieces of evidence. This survey technique has two fundamental weaknesses: time sensitivity and point-of-view.

First, crime and accident scenes are time sensitive and can be corrupted in a matter of minutes. Second, a forensic team generally approaches a scene with a theory of what took place, and if they are wrong, it may be impossible to go back to the scene for a second try. Pine Falls Technical Services — a metrology consulting firm — showed the Royal Canadian Mounted Police (RCMP) and the Winnipeg Police Department, how a laser-based imaging device could piece together the remains of a vehicle that had been destroyed by a bomb. A pipe bomb was placed under the front seat of a large station wagon. What police saw was a blast that scattered parts of the car around the pit, but left a major piece of it intact. The training demonstration gave Pine Falls’ engineers a chance to apply new technology to what has been an age-old problem of forensic surveys.

The FARO Laser Scanner is the latest in a new generation of metrology tools. Essentially, the device is a 3D camera that employs a laser as a light source, capturing the reflected image in extreme detail. A scene sweep can be 360°x 320° with a range as far as 76 meters. It captures 120,000 points per second – up to 100 times faster than most time-of-flight scanners. In forensics, a primary benefit is the fidelity and permanence of the images, plus the ability to view the image from any angle.

The test at Winnipeg showed that gathering crime scene data can now be simple and fast, quickly freeing up the area for civilian use. The destroyed car and scattered parts were digitally captured all around the gravel pit, giving a comprehensive view of what happened in the explosion. “We knew how fast the FARO Laser Scanner worked and the extreme detail of the images that it produced,” explained Doug Ursel of Pine Falls Technical Services. “It seemed like a natural fit for reconstructing crime or accident scenes.”

Learn more about the FARO Laser Scanner Photon.

All Work and No Play?

It's becoming more and more clear these days that sometimes you just need a good laugh. With all of the talk about the economy, recovery and cutbacks it's nice to take a break from it all for some good old-fashioned entertainment.

We'd like to offer you that break. Instead of our normal blog post today we would like to share a quick video with you that's sure to make you laugh. So, take a few minutes out of your busy day to enjoy this story.

Watch as Gerard, a meek Quality Control Inspector who is ridiculed by his coworkers and blamed for slowing things down, as he learns to take control of his processes – and his life.

It will be the funniest 2 minutes of your week!

View the video.

Achieving Seamless Fluid Flow in Valve Control Products

Bertrem Valve, based in Broken Arrow, Oklahoma, specializes in fluid control products. They manufacture valves and other associated products. Because their valves control the flow of fluids, it is imperative that the bolt patterns are correctly aligned and sealed in the finished assembly.

Using a traditional CMM proved to be a problem because Bertrem then had to take their parts to the fixed CMMs. Not only was this difficult and time consuming, but it prevented engineers from accurately measuring everything to ensure it would perform its job. Proper measurement and alignment is essential and the fixed CMM made it harder.

When Bertrem heard about the capabilities and time-saving potential of FARO's portable CMM, the FaroArm®, the decision to purchase was made almost instantly. The FaroArm is tough, yet lightweight, and is equipped with temperature compensators that allow it to be taken directly to the shop floor to take measurements – perfect for Bertrem’s needs. That the FaroArm is able to locate and measure the centerline of their valves was the clincher.

“We get exactly the same measured alignment dimensions (using the FaroArm) as we would in a 72-degree room on a fixed CMM,” said the Company’s President and Owner Brad Bertrem. “And this was with an ambient temperature of about 100 degrees in our machine shop at the time.”

The FaroArm’s accuracy and portability – combined with its ability to measure spheres – dramatically reduces the amount of unnecessary defects or waste during the Bertrem’s manufacturing process. The result: quality parts are easily and consistently manufactured in a timely manner.

“(We) saved enough money in the first year (with more than 100-percent ROI), to pay for the FaroArm,” said Mr. Bertrem.

Read the full story.

Total Measurement Solution for Large Machine Manufacturer

Tuftco Corporation, headquartered in Chattanooga, Tennessee, is an Original Equipment Manufacturer (OEM) of carpet tufting equipment. It is the only company in the world that can supply a carpet mill with all of the necessary machinery to take yarn from the tufting process all the way through to the finished carpet.

Weighing 20,000 to 40,000 pounds, a tufting machine is approximately 20 feet wide and has up to 2,000 needles, hooks and knives equally spaced, moving synchronously across the machine. To achieve great carpet and acceptable wear life of these and other drive components, alignment should be maintained within 0.010” across the entire span.Tuftco needs to ensure that these large machines are level, as well as verify and correct the flatness, straightness, perpendicularity, parallelism, and true position of critical surfaces and drive components such as cams, connecting links, bridges, and bearing housings.To achieve these measurements, Tuftco was using tools such as dial indicators, precision levels, scales, standard shims, and piano wire. However, these tools provided either relative measurements to non-flat surfaces or required time-consuming and disciplined procedures that were hard to enforce and consistently apply. There was also no recording of the results, and hearsay and exaggeration were not rare.

So what did they do?

Accuracy, repeatability, and support are what led Tuftco to the FARO family of products. The FARO Laser Tracker was chosen to align the frame and drive components during machine assembly as well as evaluate and align their large planing and milling equipment to tolerances that they were not previously able to achieve. Tuftco also chose a FaroArm and FARO Gage to more quickly and accurately check the critical drive components as well as verify smaller tooling fixtures.“The Laser Tracker combined with the FaroArm and Gage has allowed us to identify flaws or inconsistencies in our assembly and machining processes and redefine them to produce a machine within our required tolerances,” commented Paul Beatty, Manager of Tufting Systems Development at Tuftco. “Hard, repeatable, and accurate measurements are recorded and analyzed, and then changes are made.”Tuftco also found the FARO CAM2 software easy to use. The ability to place coordinate systems at key locations and measure relative to them has proven to be very useful. The move function has also worked well locating the Tracker in many positions in order to measure all aspects of the machine.

After having their FARO equipment for only a short time, Tuftco has already seen an improvement in their alignment by 80%. Measurements taken using the FARO equipment have also led them to discoveries about their current processes.“Many measurements that were either impossible or impractical are providing excellent insight into our sub-processes and machinery,” said Beatty. “This will lead to more consistency in parts, time-savings in rework and assembly, and a more accurate and predictable machine function.”

Read the full story.

The U.S. Economy is Picking Up

The New York Times and Bloomberg report that business activity in the United States rose more than forecasted in August, adding to signs that the economy is improving.

The Institute for Supply Management – Chicago said this week that its business barometer increased to 50, the highest level since September 2008. This is up from 43.4 in July. Fifty is the dividing line between contraction and expansion. Wall Street economists surveyed by Bloomberg News forecasted the index would rise to only 48 with estimates ranging from 46 to 52.5. Economists watch the Chicago index to gauge overall manufacturing, which makes up about 12-percent of the economy.

Additional ISM-Chicago numbers report that the new orders gauge climbed to 52.5, the highest level in a year and up from 48 in July. The production index rose to 52.9, up from 43.3.

Despite continued cautionary reminders from the Federal Reserve, these reports show business is picking up steam and suggest that the economy is finally breaking free of its deep recession. These numbers are yet a further indication that the U.S. economy is starting to improve.

Read the full Reuters article in the New York Times.
Learn more about how to benefit in the improving economy.

Check Fixtures: Complying with Six Sigma and Lean Manufacturing

Check fixtures have been a mainstay in manufacturing for decades now, allowing companies to verify that the parts they produce are within the required specifications or parameters. While check fixtures have their advantages, as technology continues to advance some major drawbacks have started to surface.

With the increasing popularity of processes like six sigma and lean manufacturing, a focus has begun to emerge around quality and the level of accuracy deemed “acceptable”. The six sigma principle, in fact, is built around the goal of producing parts that are 99.99966% defect-free. Similarly, lean manufacturing strives to eliminate waste in all its forms. Both of these processes require a method of measuring that will provide you with accurate, quantifiable results.

With check fixtures, a tool is built specific to a part to check whether the part is “good” or not by the fixture and the part nesting together. Aside from the fact that check fixtures are unique, meaning you need one fixture for every different part you produce, they are very costly to build, maintain and store. On average, one single check fixture could cost between $42,800 and $185,600 a year! That’s just for one part – what if you make multiple parts?

In addition to the high cost and inability to use the tool for more than one part, check fixtures only deliver qualitative results. This means you get a simple “go” (the part is good) or “no-go” (the part is bad) result. There is no additional data to tell you why the part is bad and furthermore, check fixtures can endure distortion over time and you may end up calling a good part bad because you can’t quite get it to fit. In tight tolerance situations, such as those that six sigma and lean manufacturing call for, you need a solution that will not only tell you accurately if your part is bad or not – but why and what needs to be done to correct it.

Learn more about what other options are available by attending the webinar, An Alternative to Check Fixtures.

Six Sigma Defined

Many companies today are implementing the Six Sigma strategy. But what exactly is Six Sigma?

According to Wikipedia, Six Sigma “seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and variability in manufacturing and business processes. It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the organization who are experts in these methods.”

Six Sigma contains two project methodologies:

DMAIC: Improving existing business process
DMADV: Creating new product or process designs

DMAIC has five phases:

1. Define high-level project goals and the current process
2. Measure key aspects of the current process and collect relevant data
3. Analyze the data to verify cause-and-effect relationships
4. Improve or optimize the process based upon data analysis
5. Control to ensure that any deviations from target are corrected before they result in defects

DMADV also has five phases:

1. Define design goals that are consistent with customer demands and the enterprise strategy
2. Measure and identify characteristics that are critical to quality, product capabilities, production process capability, and risks
3. Analyze to develop and design alternatives, create a high-level design and evaluate design capability to select the best design
4. Design details, optimize the design, and plan for design verification
5. Verify the design, set up pilot runs, implement the production process and hand it over to the process owners

To aid in implementing the Six Sigma process, many different tools can be used. Quality measurement tools such as portable CMMs have proven to be a great addition to companies looking to improve their products and processes. They continue to help quality professionals determine product defects earlier in the manufacturing process, ensuring parts meet customer standards.

Learn more about portable CMMs


Referenced from: http://en.wikipedia.org/wiki/Six_Sigma

Selling Quality and Conquering the World

Does your company actively “sell” quality? If not, you’re missing the boat. This is the premise of an article written by David Crosby for Quality Digest Daily. Mr. Crosby even provides a very fitting analogy – “How are you going to conquer the world if nobody knows you’re there?”

So how do you let the world know you’re there? You have to sell quality both to the outside world and to the inside world within your own company. Selling outside your company is meant to position your product or service, your company, in a potential customer’s mind. How do you do this? By promising quality and, even more importantly, delivering on that promise. In-house selling is essentially reminding everyone of your performance standard, your quality demands. Remind them that the product is important and so is the work they do.

Now, what exactly is meant by quality? Quality is basically two things. What many think of is parts or products that are “free of defects” or are within required specifications – that you deliver what you promised. The other definition of quality is a level of “goodness” – how good is your product compared to your competition?

A great example of selling quality is Ford’s “Quality is Job One” campaign from the 80s. The campaign sold quality to both outside customers as positioned Ford as a quality leader, selling quality in-house as it stressed the importance of quality in everyone’s job. 20 years later, when you hear that phrase, you still think of Ford and they are selling quality – to the world.

Read the full article.
Learn more about the newest quality innovations.

Manufacturing Tip: How to Accurately Refurbish Hydro Turbines and Generators

Information courtesy of Paper No. 059, HydroVision 2008 – Copyright HCI Publications, 2008

Traditionally, alignment of hydro turbines and generators is performed using both a plumb line and an optical level. The plumb line is hung down the center of the unit and is used to position all the components so that they are concentric and their axis is plumb (readings are taken with an electric inside micrometer). An optical level is used to set the components at the desired elevation.

The negatives to the plumb line is that electronic micrometer readings are very time consuming, are sensitive to outside influences, and the repeatability of readings between technicians is difficult to achieve. Negatives to the optical level are they can be affected by the vibration of neighboring units, and if the difference in elevation between the components is large, then multiple set-ups are required.

There is an alternative to these traditional alignment techniques. When Manitoba Hydro planned to refurbish its Kelsey Generating Station in order to reduce outage durations and construction effort, they investigated this alternative.

Manitoba Hydro investigated three-dimensional measurement systems before settling on a laser tracker measurement system. The accuracy, repeatability, and the time required to take measurements with the laser tracker system were proven to be superior to traditional methods.

The laser tracker functions by emitting a laser that is reflected off a target positioned at the point to be measured. As the operator moves the target from point to point and the light is reflected back to the tracker, the distance to each point is calculated.

Using a laser tracker reduced outage time by an estimated 2 to 3 weeks per unit overhaul and allowed the construction team to work more effectively and produce a better result. The laser tracker was so effective that it was used for significantly more applications than originally anticipated.

As you can see, a laser tracker measurement system can provide substantial savings in schedule and construction effort in both the refurbishment and new construction of hydro turbines and generators.

Read the entire white paper.
Read more about laser tracker technology.

GM and eBay Team Up to Sell Cars

It’s no surprise to anyone that car sales have been down. Accordingly, the government and the automotive industry have been open to looking at new ways to boost sales. One well-known plan is the popular Cash for Clunkers (Car Allowance Rebate System) program. But this plan alone won’t be enough and companies are looking for other innovative ways to jump-start sales.

As reported in the Wall Street Journal, one such plan that certainly qualifies as innovative is the joint venture rolled out by GM and eBay to sell new cars online. The idea is to let shoppers scroll through about 20,000 vehicles sitting on the lots of over 200 GM dealers – all without leaving the comfort of their own home! Like many listings on eBay, there is a “buy it now” price, but customers can also enter into online bargaining with a dealer. This pilot program is currently limited to California, but GM plans to roll it out nationwide.

As with anything new and innovative, there are skeptics. Nevertheless, GM is trying to get ahead of its competition when it comes to leveraging new opportunities and technologies. This aggressive plan is a great example of how companies need to be innovative and accepting of change in order to stay competitive. Staying with the status quo and doing things as they have always been done is a recipe for disaster. To improve processes and sales, all companies have to innovate – not just GM and eBay.

Read the full Wall Street Journal article (subscription required).
Learn more about the newest quality innovations.

Hand Tools vs. Portable CMMs

Hand-held measuring instruments have historically been popular among machinists, QC inspectors, and engineers. These instruments have been around for decades, are familiar to users. And have provided trusted results. However, there are pitfalls inherent with these devices.

For example, calipers – one of the most widely used handheld instruments in use today – exhibit measurement error through a phenomenon known as the Abbé principle. This principle states that unless the measurement object is aligned perfectly along the axis of the calipers, there will be a source of error. Other sources of errors can be the user themselves and environmental factors such as temperature.

Portable CMMs have been developed that address some these issues. As parts and products become more sophisticated, the inherent errors associated with hand tools become increasingly unacceptable. The emergence of portable CMMs that provide higher accuracy, easier reporting, and tracking of results has addressed a need in the marketplace while cutting the recurring costs associated with periodic calibration of hand tools.

Download the entire white paper.

Capitalizing on the American Recovery and Reinvestment Act of 2009

We are often asked by service providers and construction firms if we know of clients with the need for laser scanning. The signing of the American Recovery and Reinvestment Act of 2009 provides a positive answer to this question – and it leads right to the federal and state governments.

To date 6,144 highway construction projects have been approved under the act, for a total of $17.3 billion awarded out of $23.36 billion allocated to the state Departments of Transportation.

There is an additional $9 billion allocated to the Department of Energy and $1.4 billion to the General Services Administration (with an additional $5.5 billion allocated to convert federal buildings into high-performance green buildings and for building new energy-efficient federal buildings, courthouses and ports of entry).

This presents an enormous opportunity to gain new clients with the need for laser scanning, if you know how to win these contracts. Here are some tips:

1- Find proposals by visiting www.recovery.gov, or using the Search Recovery Actions option on www.FedBizOpps.gov.
2- Understand the qualifications required to participate.
3- Bid on local projects close to home.
4- Price your proposal with the understanding that many bids have come in from between 5% to 30% lower than anticipated.
5- Highlight your firm’s specialized equipment and unique skill sets. For example, a firm with a FARO 3D Laser Scanner has a tremendous competitive advantage over firms using total stations or hand measurement equipment. This is especially important in the case of GSA projects that now require laser scanning integrated into Building Information Models.
6- Partner! Large construction firms should consider using specialized subcontractors. Service Providers should seek to partner with contractors that have received awards for projects that are out of their normal scope of capabilities.
7- Once awarded, complete jobs on time and under budget to be considered frontrunners for additional projects. This provides yet another opportunity to utilize laser scanner technology that is designed to shorten the time to complete projects.

Lean Manufacturing: Getting Ready for the New Economy

While it seems that, to many people the economy keeps getting worse, there will be a day that things will turn around. Being prepared for that turn-around can mean the difference between success and failure in the new economy.

Incorporating lean manufacturing practices into your processes is just one way to be prepared. Wikipedia defines lean manufacturing as “a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination.” Now is the perfect time to look into adopting these practices when business is currently slow.

Lean manufacturing encompasses understanding the seven wastes, which originated in Japan (also known as “muda”). Toyota originally developed this idea and thus lean manufacturing was born.

If you are unfamiliar with them, the seven wastes consist of:

1. Overproduction: Manufacturing an item before it is needed
2. Waiting: Whenever products are not moving or being processed
3. Transporting: Moving product between processes
4. Inappropriate Processing: Using the wrong tool for the job
5. Unnecessary Inventory: Clutter in the work areas
6. Unnecessary / Excess Motion: Unnecessary motions of bending, stretching, etc.
7. Defects: Quality defects that result in rework or scrap

The Sioux City Journal recently reported that the company Pure Fishing is “gearing the company for growth with leaner operations”. According to the article, Pure Fishing CEO John T. Doerr said the efforts are “focusing on preparing the Penn manufacturing operation for an efficient rebound when the economy and the demand for higher-end products pick up.”

This is a good lesson for all manufacturers – take advantage of the slower times now to come out on top when the economy rebounds. It may seem like it’s a long way off, but the companies that will be successful will be ready and waiting for it, rather than those that end up being left behind.

Read the full lean manufacturing article about Pure Fishing.

Learn more about technology that can help you in your lean manufacturing efforts.

Lessons to be Learned from GM’s Fall

If one of the biggest and best companies in the world can fail, is anyone safe? The short answer is no. But, there are valuable lessons to be learned from the demise of General Motors.

David Schwinn is a full-time professor of management and worked at both GM and Ford. Professor Schwinn presented an insightful article for QualityDigest.com that explained what lessons could be learned from the GM experience and how those lessons can help other companies, even those not nearly as large as GM.

Ford revolutionized the auto industry in 1908 by listening to what the consumer wanted when they introduced the Model T – an inexpensive car in a time when many Americans couldn’t even consider buying a car. By the 1930s, consumers want more and GM listened. They offered styling, features, and choice. GM grabbed the industry lead and kept it for the next 70 years. As the leader, GM became complacent and not as quick to listen to consumer wants. In the 1970s, Japanese automakers challenged the industry leaders with superior quality. GM was slow to catch onto the quality game. When you’re the leader, it’s harder to learn.

So, what lessons can be learned from GM? GM was an example of learning at its best in their early years, but the quality of that learning waned over time. GM forgot to keep learning and it cost them dearly. I’m reminded of the quote about those who fail to learn from history are doomed to repeat it. Companies that fail to keep learning, that fail to keep innovating, run the risk of becoming irrelevant and losing whatever lead they may have once enjoyed.

Read the full article.
Learn more about the newest quality innovations.

Laser Scanning Solutions: Gilbert Engineering's Story

As previously discussed, Laser Scanning technology is transforming both forensics and surveying and appears to be a near-revolutionary game changer. Micky Gilbert, founder of Gilbert Engineering, is no stranger to forensic work. Gilbert is one of the top experts in the country, and his company has been surveying and reconstructing accident scenes for more than 10 years.

“When an attorney needs an accident reconstruction,” said Accident Research Specialist Doug Yanda, “we need accurate measurements. At scenes, we’ve been using total stations for the last few years to document critical points. At a rollover, this would be things like scratches, even shallow scratches, yaw marks, impact points and debris that police don’t pick up.”

Working with a total station was necessarily cumbersome, and required searching for small marks in the roadway and taking separate shots of each. Since Gilbert Engineering crews typically arrive on the scene 12-18 months after the actual accident, it is not always obvious which marks are important. Laser scanning has changed that, offering two significant advantages: 1) Scanning gathers everything, even shallow gouges, so scene specialists don’t have to worry about missing anything during the scene survey, and 2) The scanner works quickly so you don’t have to decide which evidence is significant to gather at the scene — you can just gather it all!

Scanning is being adopted at a steady pace in most sectors of engineering, but in the narrow niche of forensic measurement it appears to be a near-revolutionary game changer. One big reason is that the sheer mass of data gathered, which is viewed as something of a handicap by many surveyors and engineers, is a nearly indispensable advantage for those trying to ferret out the reasons for a collapse, a rollover, an explosion or other catastrophe. And once you’ve had access to all the data you’ll ever need, it’s hard to go back — especially when your opponent in a courtroom may well have access to all that data as well. At a trial, the side with the best information is likely to win the day.

And the indisputable advantages of scanning, speed and accuracy, are also a big help in this high-stakes field. It seems that this new technology has already become an indispensable component of the forensic scientist’s toolkit.

Read the full story.
Learn more about laser scanning.
Learn more about Gilbert Engineering.

3D Measurement Supports Space Exploration

With Monday’s 40th anniversary of man walking on the moon, we are reminded how far we have all come. And while Americans were the first to walk on the moon, it was an achievement for people from all over the world – it was a time that united us all.

It’s sad to think that there are only 8 more space shuttle missions and that we’ve completed 126. So what’s in store for the space program? If you haven’t already heard, it’s what NASA’s calling the Constellation Program. It includes the Orion Crew Vehicle and the Ares Launch Vehicles.

Making its first flights to the International Space Station by the middle of the next decade, Orion will send human explorers back to the moon, and then onward to Mars and other destinations in the solar system. Future astronauts will ride into orbit on Ares I, which uses a single five-segment solid rocket booster, a derivative of the Space Shuttle’s solid rocket booster. NASA’s first test flight, called Ares I-X, will provide NASA with an early opportunity to test and prove the hardware, facilities and ground operations associated with the Ares I crew launch vehicle. Data collected will begin to confirm the vehicle as a whole is safe and stable in flight before astronauts begin traveling into orbit.

If there was ever a product that required high accuracy, space vehicles definitely qualify. NASA Langley Research Center, located in Hampton, Virginia, is facilitating the buildup of the Ares I Crew Module, the Launch Abort System and the Separation Ring Assembly. With the high accuracy requirements when building these items, the Research Center has turned to laser tracker technology. Laser trackers are recognized in the aerospace industry for their portability, ease-of-use and their ability to achieve extremely high accuracy levels. The demand for this technology is continuing to increase as people realize how integrating laser trackers into their processes increases accuracy, facilitates build routines and provides real-time data acquisition. For Ares I-X, the FARO Laser Tracker is an integrated part of the fabrication process to assure the accuracy of the final product.

It’s exciting to follow the progress of the Constellation Program, and it’s reassuring to know that the parts are being inspected by the latest measurement technology. But until this program is up and running, we’ll watch with pride as the last 8 space shuttle missions remind us of how far we’ve come and how far we have yet to go.

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Benefits of Adaptive Reuse

We recently posted a story to our website detailing how a client used laser scanning to prove that a historical fire station could be renovated into a residential dwelling, while preserving the historical integrity of the structure. This project is a classic case of Adaptive Reuse – a term that is gaining great exposure due to its relation to federal and state government Green initiatives.

For many service providers and engineering firms, Adaptive Reuse can provide a source for rejuvenated business interest. What is Adaptive Reuse, and what benefits are leading to positive implications for the construction industry as new construction has slowed?

Adaptive reuse involves taking an existing building and repositioning its function. There is a popular misconception that this only involves historic buildings, but contractors experienced in adaptive reuse have made effective modifications of buildings that are only a few years old.

Federal Government Incentives
For adaptive reuse projects involving historic buildings, developers often tap into a federal tax incentive program known as the historic rehabilitation tax credit. This program generates a credit that directly reduces taxes rather than offering a tax deduction such as depreciation, which reduces taxable income. Commercial property owners who choose to renovate their historic buildings and follow certain historic preservation guidelines are eligible for a federal tax credit equaling 20 percent of the cost. A 10 percent credit is available to non-historic commercial buildings more than 50 years old.

Local Government Incentives
City governments such as Rochester and Buffalo, NY are following in the footsteps of Los Angeles, where they successfully implemented the Adaptive Reuse Ordinance in 1999. The program is run by the City of Los Angeles and coordinated by a multi-departmental effort through the Office of the Mayor, the Department of Building and Safety, and the Fire Department. The departments work as a team to quickly move projects through the design, permitting and construction processes.

The program consists of two components: a set of land use ordinances which relaxes typical zoning requirements, and adjustments to fire and life safety measures which provides flexibility in the approval and permitting process.
Less Waste (and Cost) of Construction Materials
This benefits the contractors and developers, as well as the environment. By leveraging existing building materials, the Adaptive Reuse incentives can save developers as much as 20 percent on construction costs. That also means that the resources and energy that were once used to create these structures are not squandered.

Older buildings in particular have wonderful bones from a design perspective. They have high floor-to-floor ceiling heights that allow a lot of natural daylight and good circulation. Also, buildings in particular that were built in the earlier part of the century were designed to optimize their performance in what is called the passive state. That is, being able to take advantage of solar orientation and wind and natural ventilation because the reliance on mechanical systems for comfort did not exist.

Benefits to the Local Economy and Quality of Life
Adaptive reuse usually results in lower construction materials cost, but often requires more time in labor. This means that, dollar for dollar, a renovation project will provide more funds to the local work force than a new construction project. This is good news for companies looking to find enough hours to give to loyal employees.

Abandoned buildings and vacant lots drive down property values, create a sense of economic decline and hopelessness, and invite crime. A redressing of this building stock maintains the character of our cities and bolsters our civic pride.

Having created over 10,000 apartments and condo units since its inception, the Los Angeles ordinance is credited as the city's most successful method in increasing housing stock in a short period of time. The program has also saved and brought back into productive reuse an estimated 60 buildings that potentially faced the wrecking ball.

Benefit to Laser Scanner Operators
One of the major arguments against Adaptive reuse is the advisability of planning for reuse when project schedules can suffer due to added design delays or increased burdens on documentation. Laser scanning provides one of the most efficient methods for collecting documentation of as-builts or existing buildings. Three-dimensional and BIM models are easily created from laser scan data, removing the burden placed upon the need for accurate documentation of buildings.