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Tal Vagman, profile picture
Uploaded byTal Vagman
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360 SIMS - The Power of large data for 3D metrology and process control

This document discusses how 360 SIMS (Simultaneous Multi-Station) can provide large data sets from automated 3D metrology measurements to enable process control and quality monitoring of production parts and assemblies. Key benefits include helping to reduce variation, bring dimensions closer to design intent, and pinpoint causes of quality issues. The system allows measurement of both critical features and whole areas of parts. Data is distributed to various users and systems for inspection, analysis, process control, and generating reports like the "video of the day". This new paradigm of large data sets transforms inspection from sampling to more comprehensive monitoring of production processes.

Automotive◦
Related topics:
Process Control Insights•
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360 SIMS – The Power of Large Data Set in Automated 3D Metrology & Process Control By Tal Vagman, Director Product Strategy
2 / 36 Our Goal : Contribute to Integrated Quality Production SM Stamped Parts SM Subs BiW Assembly Line Closures subs Body/Closure Engine Cradles General/ Final Assembly Final Car inspection
3 / 36 Sampling (Traditional CMM) 100% Inspection Sampling off-line vs. 100% Inspection in-line
4 / 36 Why measure Production Parts / Assemblies near or In-line ? • Help bring dimensions closer to design intent (drive to nominal) • Product Quality Monitoring, Process Control • Continuous process improvements • Pin pointing cause and guiding corrective action • Historical analysis & archiving Advantages • Faster ramp up / problem solving • Reduce rework, scrap, logistics, warranty cost
5 / 36 Reduce variation (dimensional volatility in production) Bring process to nominal or functional (CAD or Virtual Master) Process Control Motivation
6 / 36 Product Quality Development & Monitoring Upper reject limit Upper spec limit
7 / 36 Inspection Plan – Until today based on critical points only
8 / 36 With 360 SIMS: Both Area & Critical Features Measurement
9 / 36 Multi-Part Process Evaluation During Pre / Production
10 / 36 Customer Standards for Product Monitoring / Process Control OK – Within tolerance Trending – Near tolerance limit Out of tolerance Measurement Error Rejected – Stop the line Flexible setting of control limits - Each limit can trigger different action - Limits can be changed according to actual production situation - Limits can refer to % of tolerance
11 / 36 Dimensional Rules Management on Go / No go decisions OK – Within tolerance Trending – Near tolerance limit Out of tolerance Measurement Error Rejected – Stop the line
12 / 36 Distribute data to different users according to their specific needs From the Cell to the Data users In-line Station In-line Cell Data Users Quality Control Room Factory IT
13 / 36 Measurement Cell: Data Distribution to Various User Needs Operator Pass /Fail indicator Automatic PDF Report Automatic unified .cto Export to Qdas, Quirl, custom customer SPC / Reporting SW On-screen Color Map analysis Video of the day
14 / 36 Production measurement results used for Part Inspection by various Software (Customer, 3rd Party and Hexagon Metrology)
15 / 36 Flexible Post Measurement Inspection / Analysis Adding on full data set: • Adding surface points • Adding features / edges / dimensions • Re-aligning with different settings • Cross sections and adding dimensions • Exporting all types of data / reports Adding on our compressed data: • Surface points, edge line points and dimensions • Cross sections and 2D dimensions • Exporting various types of data • Generating Master part • Generating reports •
16 / 36 Process Control Life Cycle & Identifying Different Situations Stabilization during Launch / ramp up Controlling a stable process Adapting limits according To production stability & tolerance Handling less stable points Non stable critical points Temporary / limited rejections Or reworks
17 / 36 Point and Area based Process Control / Server Based
18 / 36 Process Control Tools (Features and Dimensions)
19 / 36 3D Process Control Severity and Escalation Inspection Results PLC Control/User Action Automatic transfer to next station Automatic transfer to next station with low profile alert Automatic transfer to next station with wider alert Automatic pause of transfer subject to user check and decision OK title title Rejected
20 / 36 From Fully Automated Station to User Intervention Steady state Checking data Visual inspection Analysis room
21 / 36 Point Selection and New Large Data Set Paradigm • Point selection from the pool points • For best use of time feature/surface optimization is recommended • A 50 x 50 cm tile can replaces many surface points • Features and points grouped together can be covered more effectively • With fast joint changes a full area can covered Robot Movement & wait times Robot/PLC-Communication Image Acqusition 2-3.5 sec* 0.1 sec* 0.5-1.5 sec* *Per tile
22 / 36 Point Selection and New Large Data Set Paradigm • Transform from critical points only to our added value capabilities surface colormap, xs, edge line, etc • Add multiple programs to help support various process life cycle stages • Add Special studies to even increase system value during launch and breaks Subroutine 1 Subroutine 2 Subroutine 3
23 / 36 Cycle time limited Measurements + Special Studies • 2 operating modes for special studies: • Line down time or ramp-up and initial launch periods • Running during breaks or between shifts • Examples for special studies: • Body to closure assembly (Functional & Flush and gap areas) • Interior / instrument panel assembly study • Fuel outlet assembly area • Engine assembly area
24 / 36 Back lights Assembly Area Detailed Study – Detailed AnalysisSpecial study alignment based on assembly featuresCross section 2D analysis on back light area
25 / 36 Additional Analysis as needed Special Round Edge line Measurement for F&G analysis Changing Colormap settings to support tighter tolerances Measuring all critical features and points in the area Matching Surface Point for F&G analysis
26 / 36 DRAFT 26 Patented VSPC for Problem Solving and Process Stability Analysis • Comparisons • Averages and ranges • Statistics / Trend charts • Finding closest to median • Virtual Master Part • Comparing Groups of parts • Generating unified result • Generating virtual results from statistics
27 / 36 “Image of the day” reporting
28 / 36 Patented “Video-of-the-day” – Split Screen on different areas • Patent Pending • Full shift in 60 sec clip • Part, Trend, +summary statistics visualization Roadmap: • 360 SIMS DataServer enabled • Automated generation • Distribution to user / mobile devices
29 / 36 Patented “Video-of-the-day” – Split Screen on different areas
30 / 36 In Future – more actionable data into the video report
31 / 36 Small and Large Data set Cell Monitoring 3rd Party Integration QDAS/SPC Mobile Reports Generation Video of the day generation Search results More Ways for Using and Accessing the Metrology DATA Metrology Database Application Server • Server provides access to users and application to all managed data
32 / 36 The Data Challenges We create a lot of data and needs to be: • Stored • Distributed • Managed
33 / 36 Data Management and Storage - Recommended Cell Data Server (all measurement results) • 6 months of data advised • Older then that to be backed-up on archived storage in IT room Network File Storage (.cto, PDF, Pics, Videos others) • Very short term saving of full projects (GBs per measurement) • Naming convention based on customer wishes • Unlimited storage but requires periodical maintenance Customer SPC / IT systems (f.i., csv, dmo, DFQ, quirl, etc) • Agreed formats saved for automatic processing by customer system
34 / 36 Page 34 ~50 Mgb per part 700 parts/day 35 Ggb per day Saved time, 6 months ≈ 6.4 Tb
35 / 36 Casting Measuring Cell Our Vision: Integrated Metrology Solutions Leveraging 360 SIMS, MMS and Q-DAS Platforms for Actionable Workflows F&G Measuring Cell Assembly Worker Quality Analyst Closure Measuring Cell MMS Application Server Metrology Database BiW Measuring Cell • Data from all measurement systems is collected and managed Connecting various metrology systems in the factory with the different users for quality data
Thank you !