ISMR July/August 2021 | Page 60

INSPECTION AND MEASUREMENT

completely re-assess their entire value chains , and apply different ways of thinking and toolsets , fusing the physical , digital and virtual worlds together . Industry 4.0 encourages the integration of intelligent production systems and advanced information technologies . It is fundamental to the foundations and future of many of the world ’ s leading manufacturers .
The promotion of a digital manufacturing strategy is fundamental for many manufacturing companies if they are to remain competitive in the years to come . Central to this is the capture , analysis and alteration of data . From this perspective , the role of 3D metrology solutions is clear , and it is very much more than just catching the occasional QA failure in production .
The power of metrology-driven data
For Industry 4.0 , the use of Big Data is key as is its movement and use upstream and downstream in the product development process . Algorithms adjust the manufacturing process to ensure consistent , efficient and , above all , repeatable production with zero failure rates .
3D data is captured as parts are manufactured using fast , non-contact optical metrology systems and can be directly fed to the quality control team who analyse its conformance with design intent , by comparing it with 3D CAD solid models . Any areas of concern can be highlighted , and adjustments can be made instantaneously to CAM files .
Such an automatic process all but negates the need for shut-off , drastically reduces failure rates and scrap , and therefore enhances the overall efficiency and costeffectiveness of production . In such a scenario , advanced 3D optical metrology solutions enhance the quality , quantity and speed with which data is collected , and allows its analysis and significance to be assessed in the blink of an eye to enhance manufacturing processes .
Smart Factory metrology solutions
Metrology ’ s role in highly digitised factories which continuously collect and share data through inter-connected devices , machines and production processes is to support digital production at every stage . To achieve the objectives of the “ smart factory ”, manufacturers must evolve their processes to close gaps in inspection-related data at every stage in the production value map .

About Zygo

Zygo Corporation is owned by AMETEK , Inc ., a global manufacturer of electronic instruments and electromechanical devices with annual sales of approximately US $ 5 billion . Zygo is a worldwide supplier of optical metrology instruments , highprecision optical components and complex electro-optical systems . Its products employ various optical phase and analysis techniques for measuring displacement , surface shape and texture , and film thickness . Zygo also has expertise in optical design and assembly , and highvolume manufacturing of precision optical components and systems for the medical / life sciences , defence and industrial markets .
It also has a role in giving manufacturers greater visibility of the entire supply chain , including suppliers . Smart factories bristling with industrial robots and automated handling systems rely heavily on fully automated control systems and speedy verification and feedback .
This plays to the use of in-process metrology solutions and non-contact 3D optical solutions .
Typically , the conversation when looking at the optimum use of metrology in advanced manufacturing settings today is between its use in the lab or in-process . Ultimately , a key driver for the shift from in-lab to in-process is a desire for a “ faster time to data ” and , more importantly , the ability to make decisions faster as a result . Hence , it is a key element of Industry 4.0 and the efficient running of a smart factory .
When compared to alternative legacy metrology solutions , where measurement is a separate off-line activity , in-process solutions have several key advantages .
To achieve the objectives of the “ smart factory ”, manufacturers must evolve their processes to close gaps in inspection-related data at every stage in the production value map .
The most obvious is the speed at which the data derived from it can influence decisionmaking . If carrying out metrology in-lab , parts must be moved to the QC department and then they need to be set-up for the metrology operation to be undertaken . If the metrology is in-line , various process steps are removed and as defects and problems can be identified and rectified instantaneously , reworking is reduced . In-process metrology therefore assists in preventing problems before they arise , and if they do arise allows them to be identified and addressed before they become a costly and time-consuming issue .
Non-contact optical metrology solutions also fit within the concept of Industry 4.0 as they are speedier and can cover larger areas than contact devices . Fully integrated 3D optical metrology promotes fully automated closed-loop production . In addition , improvements in computer processing and optical technology mean that the sheer amount of data that can be acquired and analysed is vastly increased . 3D optical metrology solutions used in-process allow for processed data to be to be fed from the metrology system into the factory management system . This considerably advances the concept of the smart factory .
In conclusion
For automation to be successful in the Industry 4.0 era , data collected for monitoring and control must be reliably communicated . As part of this trend , incorporating metrology equipment into manufacturing systems to gather data for use in intelligent decision-making prevents process variation .
More intelligent , more flexible and faster learning metrology systems are at the heart of — and integral to — Industry 4.0 and all advanced manufacturing systems . Such metrology systems promote the evolution of connected factories and will dramatically reduce downtime whilst speeding up production of more innovative , better designed and higher-quality products .
While there are many developments on the horizon in this area , forward-looking companies should be examining advanced metrology solutions in the market today which can be used to enhance manufacturing efficiency at all levels . n
60 | sheetmetalplus . com | ISMR July / August 2021