The 32-year-old and his six-member team inspect the raw castings with particular care, “as defects in casting cause exponentially higher costs with every step in the value creation chain.” After each series of 200 to 2000 cast parts, the inspection of a part with the ZEISS T-SCAN is obligatory for the top-selling cast parts.
Samples are taken as well. For a more detailed analysis, the operator imports the generated measurement data into the ZEISS CALYPSO software, which checks the dimensional, form and positional tolerances. Reporting and statistical data analysis are then completed in ZEISS PiWeb.
The team reviews the scrap statistics every two weeks, discussing what can be done to optimize the defects in the corresponding areas. ZEISS T-SCAN provides the reliable base data and documents success based on the geometry and form of the parts.
A false-color comparison immediately shows whether the cast part is within tolerance and whether the part is over or undersized. With just a few mouse clicks, he generates a report for the coordination with the surface processing department. “It doesn’t get any more intuitive than that,” comments Emini.
Data For Final Grinding
Thanks to continuous measurement with ZEISS T-SCAN and constant adjustment of the grinding parameters, the robots now work both precisely and very quickly. Because the company’s own capacity still doesn’t always suffice, part of the grinding work is outsourced to smaller firms. Then ZEISS T-SCAN is used for quality assurance during the incoming goods inspection.
The quality team also recently purchased a ZEISS Smartzoom digital microscope. “We use the microscope to look for defects in the metal structure that are not visible or difficult to see with the naked eye,” explains Michael Wage, Head of Surfaces at KWC, who is satisfied — if not downright impressed — by the microscope’s performance. The company is also planning the replacement of two older coordinate measuring machines with a ZEISS CONTURA CMM. For Emini there is no alternative: “For me ZEISS is the absolute superlative in measuring technology.”
For more information: www.zeiss.com/metrology