CMM Productivity and Internal Rate of Return (IRR) to justify a new Acquisition

K

KP USA

#1
Hi all,

I need to do an internal rate of return calculation for a new coordinate measuring machine and have a corporate template to do this. I also have Hexacon's (B&S) white paper that includes a lot of good information in spite of the obvious conflict that its from a CMM manufacturer (and we are looking primarily at the B&S Global CM, which is programmable and automatic.

The X factor is what kind of inspector productivity increase will we see. We currently use a FARO Arm and a variety of manual gauging, although we found the FARO is borderline for tighter tolerances when we did an R&R study. We measure a variety of aircraft parts produced by contract build-to-print machine shops. Tolerances can be tight, although we would probably use hand gauging for .0005" or even .001" OD and ID's.

Our throughput will increase considerably next year (double or triple). Does any one have real world before and after experience that might help?
 
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Kingsld1

Involved In Discussions
#3
This is 25-30 year memories but I'll give it a go.

When I first started in QC our twenty some odd first shift inspectors were using a mix of vernier, mechanical digital, and electronic digital height gages and hand tools to measure parts. We also had a Manual CMM. Setups and lot inspections were performed.

We were working on defense contracts; using a fair amount of GD&T.

A few years later the company bought a pair of DCC 1808 Cordax CMM's equiped with PH9 rotating heads. After settling in on how to use them we wound up with 2 to 4 people doing setups and in process inspections using the CMM and 6 or 7 people double checking paperwork and running thread and plug gages in a finished lot.

Having an automatic CMM means that other things can be done while it's busy beeping away. Having a consistent measurement method helps as well. Right, wrong or indifferent, it's consistent. It's easier to track down why one method is giving a weird result than 20 methods.
It would not be out of the question for a layout taking 20-30 minutes by someone really hustling to only take 5 minutes.

By the way, I would be careful of using a CMM to measure diameters. The CMM by default uses a least squares method of determining hole size. This works OK until holes start going out of round. (Hole locations are still good)
There are ways around this but they involve going off the default for each hole, taking lots of points or scanning etc.

Might want to look into buying/making a couple of fixture plates and standoffs. Programs can be written to where they are 'load and go'. Multiple quantities of the same part can be setup and ran as well further increasing the amount of time that an inspector could do something else.
 
K

KP USA

#4
Good stuff, Kingsld1. Thanks. That gives me some real world experience in a similar inspection environment. :)

A few followup questions, if you or anybody can spare a few more minutes:

You alluded to repeatability with the Cordax automatic CMM vs manual CMM and gauges. Could you share your expereince here regarding comprison of repeatability and/or general quality of results?

Your point on the holes is well taken and validates what we have heard elsewhere. Regarding threaded hole location, do you have experience with using precision threaded inserts so a pin (on center with the threaded hole) is used to probe as the centerline rather than trying to pick up the threads? We would use a thread gauge for the thread checks.

Thanks again,
 
S

Sean Kelley

#5
Might want to investigate some newer measuring methods using lasers. The equipment tends to be much faster and has a lower up front cost typically. It may not work for your applications but I would give it some thought.
 

Kingsld1

Involved In Discussions
#6
Regarding repeatability, it just like any other time two different gages are used to measure something. There will be differences. The CMM is little more difficult to understand the differences. Often the way the part is setup is different on the CMM than the way the surface plate method is. Also, discrete points are used for both alignment and features. There is kind of a chicken and egg thing going on with the number of points to take per feature. If the feature form is excellent fewer points are needed. On the other hand, you don't know the form until the points are taken and/or you have a good idea of the form that your process creates.

I have used precision threaded inserts in the past. They work well but are a major pain to install, remove and keep track of. If the best possible accuracy is needed, they are the way to go. If you are looking at Brown and Sharpe CMM's, their software PC DMIS offers another option. Basically it involves telling the machine what the thread pitch is. The probe will then contact the thread form at the same RELATIVE place as it spirals down the hole.
 
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