It's 'Metrology', NOT Meteorology: And Why It's Nothing to Fear

From seasonal hurricanes and tornados, to blockbuster winter storms, meteorology can pack a punch. In fact, a recent study on just one thunderstorm over India estimated it contained 1.3 billion volts. It's a shocking statistic that for many underscores a natural fear of the weather and even the words associated with it. After all, meteorology contains the word meteor – as in de-orbiting giant rock.

But there's another word in the English language that sounds a lot like meteorology that also sends shivers down peoples' spines but it shouldn't: metrology. While they share most letters in common, meteorology is the science of weather and climate while metrology is the science of measurement and weights. And it is the science of measurement (and the tools associated with its applications) that small and medium-sized businesses (SMBs) should be paying particular attention to – regardless of the weather.

In fact, metrology need not be scary at all. Nor should SMBs assume they require special skills or a mathematical degree to master the technology. Today, thanks to advanced and easy-to-use 3D measurement hardware (such as portable measurement arms) and software, metrology has become an easy and straightforward applied science. Especially when compared to accuracy-challenged hand tools, bulky fixed coordinate measuring machines (CMMs) and similar products, operators can measure anytime, anywhere, including while the part is still on the machine producing it. Not only that, but businesses that adopt such metrology solutions (and their clients) will benefit by having a permanent digital record of the inspection report. Transparency and efficiency at its finest.

A Sunny Forecast for Portable 3D Measurement Arms

So, what is meant when referencing the metrology tools of today? For the purposes of this article, they are the portable, digital tools intended for product build and verification. The small and medium-sized industries where metrology comes into play are diverse and include: machine shops, casting, forging, fabrication, tooling, and mold & die, manufacturing/machine assembly.

Tools like the FaroArm^® is an excellent example of what transportable, digital measurement is all about. The new FARO^® Quantum Max ScanArm, for instance, allows for confident 3D measurements across a wide range of machine shop and industrial applications as it combines the measurement capabilities of a Quantum Max portable coordinate measuring machine (CMM) with the non-contact functionality of a laser line probe. The Quantum Max also offers three laser line probes that optimize accuracy, speed or a blend of both, depending on project need.

Like its predecessors, it is ideal for small size, high-accuracy tasks, and vastly improves upon and replaces multiple hand tools like micrometers, calipers, and height gauges thanks to its convenience, speed, and ease of use. With a product like Quantum Max, inspection bottlenecks are all but eliminated, along with operator variability – a factor that can make the difference between small business profitability or loss.

In the case of Quantum Max, the collected data is stored directly on a computer and compared against the original CAD data. CAD Data? Sure – your computer numeric control machines (CNC) machines are driven by CAD data, so why not verify and measure using the same nominal data that is used for machining? No CAD data, No worries? As long as you have a referenceable nominal measurement spec such as a blueprint, you can still use these tools. All of this is a way to ensure that the part measured is verified according to the original design specs. And it helps ensure that part rejects and scrap are reduced to a minimum.

Quantum Max is but one example of how innovative and affordable 3D metrology tools can help a small or medium-sized business punch above their weight. Another group of products are laser trackers. These are best suited for large-scale 3D measurement. Laser trackers measure angles and distance. It really is as simple as point and shoot and is ideal for assembly alignment, part and assembly inspection, machine installation and alignment, and reverse engineering. For instance, instead of measuring each individual part for a boat assembly by hand, laser trackers can measure entire hulls. As in the case with all digital models, the measured specs can be compared to original design specifications, whether they are CAD or blueprints.

In rounding out the 3D metrology hardware trifecta, there's also the burgeoning field of virtual templating which uses laser-guided assembly projection. These devices project a visible laser outline onto 3D surfaces and objects which assemblers use to sequence work and position components. Think of it like the paint by numbers approach to 3D metrology. All operators have to do is match the part to the image outline and the assembly is complete.

CAD-based virtual templating eliminates the need for physical templates and hard tooling, which like other digital solutions, reduces the risk of human error and costly rework. With these tools manufacturers can avoid the time and expense associated with using large, heavy templates while significantly improving quality control.

Long Range Outlook: Steer Clear of Fear

For small and medium-sized businesses that have never worked with products like these, some trepidation is natural. Many SMBs work with as few as 10 manual measurement tools and making the jump to computer-based 3D measurement can feel daunting. But it shouldn’t.

One of the most common concerns is that the technology itself is too precise. That is to say that it generates too much data that the information overload will frustrate staff. Or that it will show alignments so slightly out of tolerance relative to the original design specs that ' not worth correcting the error. (Which, goes the internal debate, why purchase a measurement tool in the first place if all it does is tell me things I don't need to know.)

But as any seasoned professional knows, ignorance is not bliss; it's ignorance. 3D measurement isn't about upending your existing processes. Rather, tools like the Quantum Max, laser trackers and virtual templating, all help identify problems and errors further upstream in the manufacturing process. The sooner an error can be detected the less scrap and re-work and overtime costs are generated. For SMBs with high throughput, alignment errors, even if ' only a small percentage of your product output, can become expensive fast. The smart application of 3D metrology allows manufacturers to avoid multiple “profit killers”:

• Rework and scarp
• Putting additional manufacturing time and costs into parts that are out of tolerance and would not pass final inspection – perhaps the costliest example of scrap and rework.
• Shipping non-conforming products to customers which is not only costly, but the resulting customer dissatisfaction could lead to lost contracts and revenues.

So is metrology scary? Not anymore. In fact, not embracing 3D metrology at all might be what is really scary.

'Spring Forward' with Leadership from the Top

To be sure, whether you're a meteorologist or a metrologist, it helps to gain a little guidance from someone higher up, the proverbial “bigger fish” in the pond. (To keep with our weather/natural theme.)

In this case, SMBs would be wise to take a page from their larger competitors. Or at the very least, take note of the broader industry trends. Large manufacturer or small, it should be clear by now that 3D measurement technology is a valuable addition not only when it comes to inspecting a final product, but throughout the entire machining process, accelerating time to completion, while simplifying workflows.

In the years ahead, as 3D metrology continues to advance into all aspects of manufacturing a growing number of SMBs, like their big business brothers, will embrace this technology. And increasingly, 3D measurement tools will be integrated into smart factory applications and throughout the machining workflow process, whereby even more data will be collected and acted on and shared. Portability, “pause-ability” (to identify any potential issues straight away and correct the machine program in less time) and in-process alignment are the key drivers of success today's machinists, large or small, are eager to embrace.

Even now, the students of today, as evidenced by the signups for a new 12-week program at The Greater Ozarks Center for Advanced Technology, or GOCAT, in West Plains, Mo., are learning the automation manufacturing skills of tomorrow. If such educational momentum is building in a small American city sandwiched between the Mark Twain National Forest and the Ozark National Forest, you can bet other institutions of learning are taking note.

Thus, adopting these solutions now may be just the competitive differentiator your business has been looking for to stand out from the crowd — not to mention a new “tool” in its talent acquisition armamentarium.

Now that's a revenue and profitability boost that'll be sure to “make it rain”.