The Power of Precision: Insights from Jeff Frey on Metrology and Automation in Manufacturing

Precision plays a crucial role in the manufacturing process, ensuring that components are created according to strict specifications to reduce waste, maintain quality control, and enhance customer satisfaction. The +Vantage Assembly & Metrology Division of Acieta knows firsthand how essential precision manufacturing is to a successful process.

As a Final Test Engineer at +Vantage Assembly & Metrology | Acieta, Jeff Frey knows how important precision measurement is in ensuring product quality and process control in manufacturing. Here, Frey shares his expertise on metrology, automation, and the future of the industry.

Automating Inspection for Improved Efficiency

One of the projects Frey has worked on is developing a “snapshot gauge” system for inspecting mufflers. This innovative automation system utilizes a robot to load the mufflers and move them into place so the structured light sensors can efficiently evaluate parts, checking them against customer specifications and GD&T requirements.

The snapshot gauge offers several advantages over traditional inspection methods:

• Inline process control for 100% inspection
• Reduced cycle times by eliminating transport to a separate CMM
• Quick changeovers for inspecting different part types
• Minimal training required to operate
• Process control and measurement of critical features without risk of contact damage like standard gaging methods
• Flexible system allowing the ability to add more cameras if customer requirements change, or measurements need to be added

By integrating precision measurement directly into the production process, manufacturers can reduce scrap, improve throughput, and ensure consistent quality.

The Importance of Precision in Manufacturing

Frey emphasizes that precision measurement is essential across all aspects of manufacturing. “Measurement is in everything we do in this industry,” he says. “For you to have a reduced amount of scrap, and for you to control a process, and for you to make a proper part, you have to measure it.”

He goes on to say that it helps to integrate these processes so they happen simultaneously. “So we do the robots, the cell, the automation, the safety, and the measurement,” says Frey.

Precision manufacturing delivers several key benefits:

• Tighter process control
• Reduced scrap and waste
• Assurance that products meet customer requirements
• Ability to work to micron or sub-micron tolerances when needed

By investing in precision metrology, manufacturers can optimize their processes, minimize errors and quality issues, and ultimately produce better products.

Collaborating for Quality

Frey stresses the importance of close collaboration between +Vantage Assembly & Metrology | Acieta and their customers to ensure measurement accuracy and reproducibility. This involves conducting repeatability and correlation studies to confirm that gauges are measuring parts consistently and are in alignment with customer CMMs or other measurement systems.

Working hand-in-hand with customers enables +Vantage Assembly & Metrology | Acieta to:

• Resolve any discrepancies in measurement methods
• Fine-tune gauges to match customer requirements
• Provide a product that meets all quality objectives

This collaborative approach is key to overcoming the inherent challenges of precision machining and delivering reliable solutions to meet strict metrology standards.

Harnessing the Power of Data

Frey explains that one of the most exciting developments in metrology is the rise of point cloud technology and structured light scanning. These tools provide a wealth of data that can be used for process debugging and optimization.

Point cloud data enables manufacturers to:

• Gain a comprehensive understanding of part geometry
• Identify issues that may not be apparent from GD&T callouts alone
• Streamline root cause analysis and problem-solving

By leveraging this important data, manufacturers can uncover valuable insights to drive continuous improvement.

The Future of Automation in Manufacturing

As automation and metrology continue to evolve, Frey sees significant potential in the application of artificial intelligence (AI). He cites the example of using AI cameras for weld inspection, a notoriously challenging application that can be greatly simplified with this technology for enhanced precision in manufacturing.

Moving forward, +Vantage Assembly & Metrology | Acieta remains committed to staying at the forefront of metrology and automation. By continually evaluating new cameras, software, and technologies, we aim to provide our customers with the most accurate and efficient solutions possible.

The Path to Automation Success

For manufacturers looking to automate their processes with advanced manufacturing solutions, Frey offers this advice: focus on truly understanding the function and requirements of your part. “As long as you have a really good part print, and you know what you’re trying to achieve through that, automation really isn’t that complicated,” Frey says.

By combining precision measurement in manufacturing with well-designed and integrated automation, manufacturers can enhance quality control measures, reduce errors, and improve efficiency. As Frey and the team at +Vantage Assembly & Metrology | Acieta demonstrate, the power of precision is transforming manufacturing–one part at a time.

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