- Monday, March 22 - Workshops
- Tuesday, March 23
- Wednesday, March 24
- Thursday, March 25 - Plant Tour
| 12:00pm- 5:00pm |
Early Registration Open | ||
| Workshop 1 | Workshop 2 | Workshop 3 | |
| 1:00pm- 5:00pm |
Accreditation Guidance for the Interpolation and Extrapolation of Calibration Data James Jenkins, Laboratory Accreditation Bureau This workshop will provide guidance on the subject of both interpolation and extrapolation of calibration data as it relates to calculating measurement uncertainties and the expression of those uncertainties on both the client’s scope of accreditation and any accredited calibration or testing reports as defined by the Laboratory Accreditation Bureau. |
Basics of Ultrasonic Weld Inspection Daniel Kass, Olympus NDT This hands-on workshop will introduce use of ultrasound for the testing of welds. Conventional UT and Phased Array techniques will be outlined and then applied to actual samples. While focusing mainly on construction welding, component weld testing will be briefly outlined. Participants are welcome to bring small sample components that may be of particular interest. |
Rapid Conversion of Legacy Parts into Native CAD Models |
| 5:00pm- 6:00pm |
Cocktail Reception | ||
| 7:30am- 8:30am |
Continental Breakfast and Registration | ||
| 8:30am- 8:45am |
Welcome Address Tom Williams |
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| 8:45am- 9:30am |
KEYNOTE: Quality and the Rebuilding of a Legend at Smith & Wesson Ken Chandler, Smith & Wesson Smith & Wesson is a legendary firearm company that is broadening into a company focused on safety, security and protection. With a history going back to 1852 and recorded in famous paintings by Frederick Remington and other artists, its reputation for high performance, high quality precision and ruggedness in its products is a result of its longstanding focus on designing and manufacturing innovative solutions that are unparalleled in its market. Over the past five years, Smith & Wesson has been revitalizing its operations to sustain its image for quality products and to provide a platform for growth. In his keynote presentation, Ken Chandler will talk about how the company has increased operational availability while continuously improving its quality levels. |
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| 9:30am- 10:15am |
Quality Plant of the Year Award Presentation: Mark Nash, Pelco Products, Inc. John Miller, Pelco Products, Inc. Starting out as a manufacturer of niche products for the traffic industry, Pelco has grown into the largest traffic signal hardware manufacturer in North America. Diversification has added ornamental lighting and accessories as well as brackets and other accessories for the utility power industry. In this presentation, Mark A. Nash and John Miller with Pelco, provide the rich history of the company and its journey towards the epicenter of efficiency. The growth of the Pelco team is explored along with the process to empower the workforce, and the impact this strategy has made on the quality of Pelco’s products. Through this strategy, the quality and management teams were able to identify the strengths and weaknesses of the quality system and take appropriate action to turn Pelco’s quality system into a catalyst for growth. Playing off of the demands of the customer and desires of ownership to meet these demands, the results far surpassed the goals and objectives of the Pelco strategic quality initiative started in 2008. To date, Pelco has not only employee and customer gained acceptance of the quality system, but has received state and national recognition for creating a quality system that relies on and believes in the empowerment of the employee. |
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| 10:15am- 10:45am |
Morning Break | ||
| 10:45am- 11:30am |
A Practitioner's View of Measurement Systems Analysis Dean Beutel, Caterpillar, Inc. Measurement of production components has been required since the introduction of mass production. As demand for improved product performance has increased component feature tolerances have tightened, thus increasing the requirement for precision gaging. A corresponding cost increase has accompanied these events. The desire to manage and control cost has driven the need to precisely define and specify gaging, ensuring adequacy, but not over specification of gages. Several general "rules of thumb" have developed for gaging, as well as a number of national and international standard requirements. This discussion will look at some historical gaging information and the current state of defining, specifying, and testing gaging systems. |
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| 11:30am- 12:15pm |
Small Things Considered: Measurement of Sub-Millimeter Features Ted Doiron, NIST In this presentation Ted Doiron will share new capabilities for contact measurements of sub-mm features. In a study three different probe systems using different technologies have been tested against each other for features between 1 mm and 0.050 mm. This study includes the sizes where the probes ranges overlap. Ted will explore the uncertainties related to each probe, and present the results of customer calibrations. |
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| 12:15pm- 1:30pm |
Luncheon | ||
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| 1:30pm- 2:15pm |
Measurement-Driven Lean Enterprise Success in Manufacturing Leo Barry, Plexus Electronic Assembly Maximize your data utilization! Presentation describes a measurement-driven strategy integrating optical, x-ray and electrical tests into core process metrics. Trending tactics highlight common and special cause opportunities. Lean Enterprise teams achieve and maintain improvements across business boundaries. The system is deployed globally by Plexus, a $1.6 billion contract electronics manufacturer servicing hundreds of customers from general industrial to regulated medical products. See how you can help your organization obtain similar benefits. |
Comparison Between 3D Metrology Results Gained With Conventional CMM and High Resolution X-ray Tomography David Lehmann, GE Sensing & Inspection Technologies High resolution X-ray tomography is currently evolving from an established qualitative analysis method to become a powerful quantitative tool which can e.g. be used for high precision 3D dimensioning. For this application the quality of the measured CT data-set significantly determines the accuracy of all following 3D measurements. To achieve high precision metrology results, the reconstruction algorithm has to take into account and correct inevitable physical effects which occur during CT data acquisition like beam-hardening. The traceability of the CT measurements results, which are generated by advanced surface extraction algorithms, is ensured by calibrated and certified test specimen. |
The Current State of Open Source Software in Error Proofing and Vision Systems Anthony Oliver, CEC Controls The use of open source software in error proofing and vision inspection has significantly increased versus proprietary software. Is this the right choice? This presentation includes an overview of the need for such software and common applications. It also includes a discussion of the cost vs. time trade-off required to decide whether open source or proprietary software may be preferred. Anthony Oliver will also give several examples of open source software that is currently available, and he will compare and contrast it to proprietary software and mock applications for cost projections, with a breakdown of the pros and cons of each. |
| 2:15pm- 3:00pm |
Innovations in Machine Tool in Process Measurement and Feedback Ray Karadayi, Applied Automation Technologies, Inc. Dimensional measurement on machining centers has been done on simpler geometric features and mostly for part location. In recent years, collecting dimensional data on more complicated geometrical features as well as sculptured surfaces became necessary. First the measurement data is made accurate for any probing directions by developing smart probe calibration processes on machine tool probes for up to 6 axis. Developing a CAD based measurement environment with virtual machine modeling and a real time interface with a machine tool controller enables complex calculations and processing for any type of features or CAD model comparisons. Whilst offline programming allows development of a probing program directly from a CAD model independent of the machine tool, post processing enables to execute this program on any machine tool with ease of use similar to any other machine tool program. |
An Automated and Quantitative Method for Quality Assurance of Digital Radiography Imaging Systems Steven A. Mango, Carestream Health Inc. - NDT Solutions As the transition to digital imaging technologies continues to gain momentum in the NDT industry, users are concerned with monitoring the performance and stability of their imaging systems. Industry standards (ASTM, CEN) have defined test phantoms and methods, but many users are finding these cumbersome to use and/or too pricey. As a result, several military and government defense contractors have developed lower cost alternatives, but these still require tedious and sometimes subjective analyses. This presentation will describe a unique phantom and an automated method for the quality assurance (QA) of digital imaging systems, providing a simple and quick way to quantitatively measure the key characteristics of storage phosphor-based computed radiography (CR) imaging systems and direct-digital flat-panel detector-based direct radiography (DR) imaging systems. |
Smarter Cameras: How Today's Software Takes Smart Cameras to the Next Level Bradley Weber, PPT VISION, Inc. Smart cameras provide many benefits in a wide array of applications, including code reading, assembly verification, and package inspection. Each of these applications needs to ensure that no defect is missed. Due to the wide variety of applications and ongoing innovations that differentiate one manufacturing process from the next, inspection needs are unique. Though two machine vision applications may involve inspecting similar parts, each manufacturer may require different inspection criteria, such as product size or surface defects. This uniqueness also extends to the user interface – some companies want their operators to have access to all inspection parameters, while others prefer more limited access. |
| 3:00pm- 3:30pm |
Afternoon Break | ||
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| 3:30pm- 4:15pm |
Gage Control After Calibration Rick Sloop, InfinityQS International Controlling and maintaining gauging is a must for any measurement system. However, many manufacturers miss opportunities because they don’t really understand the entire gage control cycle. Measurement System Analysis (MSA) ensures that measurement systems are acceptable, routine Calibrations help ensure that gages are working properly, but how do we control the gauging system between calibrations? This presentation takes MSA and Calibration a step further and provides a better understanding of the entire gage control cycle, with a focus on the often overlooked portion of gage control, routine gage stability evaluation. |
Using Phased Array for Weld Inspection Daniel Kass, Olympus NDT Like many other nondestructive testing methods, ultrasonic flaw detection has been a valuable quality assurance tool for many years. The reflection and transmission of high frequency sound waves has long been an important tool for evaluating the integrity of welds. Over the past couple of decades these inspections have been improved by the now completed transition to fully digital instruments that greatly aid interpretation and measurements. This presentation will discuss transitioning from conventional UT to phased array, as well as the application and benefits using this growing technology for weld inspection. |
Understanding Machine Vision Lighting Techniques Daryl Martin, Advanced Illumination The focus of this presentation will be to present basic machine vision lighting concepts and explain them from a technical aspect. Lighting geometries, spectral considerations, camera/lens/light interactions and the impact of part surface finish will be discussed as they relate to the desired image. Example images will be used to illustrate how these factors impact an image. The end result is to prepare the attendee to specify and select a machine vision lighting system.
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| 4:15pm- 5:00pm |
Rapid Reverse Engineering with 3-D Noncontact Products Dan Snigier, Nvision 3D The need to replace or optimize aging but essential equipment originally designed in a pre-CAD era is a problem that crosses all industries, from aerospace to power generation. Parts and equipment designed without benefit of CAD technology often lack the critical documentation and data necessary to create accurate computer models for analysis and/or reproduction. Reverse engineering - often a costly and time-consuming process is therefore required in order to create CAD models that are utilized to analyze and improve the design. 3-D noncontact measurement systems offer a faster, more accurate alternative to traditional reverse engineering methods such as calipers, gages, and CMMs. In this presentation Dan Snigier will explore this specialized software that can improve processes. |
In Line Eddy Current Systems William Buschur, ibg NDT Systems Corp This presentation will focus on pictorials and videos of actual systems for material properties (heat treat & alloy) and crack testing on automotive components, including steering racks, strut rods, drive shafts, bearing components, CV joints, forgings, con rods, ball studs, tie rods, spindles, cylinder liners, carnshaft lobes and others. Technical considerations include the important basic technical requirements the applied eddy current methods must meet in order to make testing highly reliable, with high resolution and repeatability, and with easy implementation and use, including multiple frequency tests for heat treat and multiple filter tests for cracks. |
Color-Based Recognition vs. Color Measurement - Why They're Different and Why It Matters Robert McConnell, WAY-2C Color Machine Vision Most humans, not to mention birds, bees and other creatures with less computing power, are born with the ability to recognize objects based on their colors. Many inspection tasks can be quickly and accurately accomplished by human inspectors based primarily on color distributions. The ability to quantify and measure color is a relatively recent development. This can be critical in maintaining appearance within specifications. Failure to properly distinguish color-based recognition and color measurement regularly results in overlooked inspection automation opportunities, unnecessary costs, and/or disappointing system performance. |
| 5:00pm- 6:30pm |
Welcome Reception | ||
| 7:30am- 8:30am | Continental Breakfast and Registration | ||
| 8:30am- 8:45am |
Opening Remarks Tom Williams, Quality Magazine |
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| 8:45am- 9:30am |
KEYNOTE: GD&T - Friend or Foe? Edward Morse, University of North Carolina, Charlotte Geometric Dimensioning and Tolerancing (GD&T) is a means of specifying unambiguously the required geometry that a part must have to be considered acceptable. National and international standards have been developed to define the syntax (symbols) and semantics (meaning) for geometric part specification. The ASME Y14.5 standard (both 1994 and the newly-released 2009 version) explicitly states that it is "not intended as a gaging standard" and thus the interpretation of the part inspection results is often left to the user of the equipment, either with or without the help of measurement software. |
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| 9:30am- 10:15am |
Quality Professional of the Year Award Winner Dean H. Stamatis, Contemporary Consultants and University of Phoenix - Detroit Campus In this presentation Dean Stamatis will discuss qualitative measurement and America’s future. He will begin by defining measurement and then explore the approaches to measurement. In addition, it makes the link of measurement with quality and explains how measurement and leadership can play a major role in America’s future. This link is exemplified by three principles drawn from General G. Paton as they relate to measurement: a) We are indeed in an economic war through globalization b) Americans like to fight. They hate the idea of loosing. They play to win, and c) Have long-range scope. Dean will close the presentation with the notion of being a winner in the long term through teams and emphasizing that appropriate and applicable measurement is the road to future success! |
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| 10:15am- 10:45am |
Morning Break | ||
| 10:45am- 11:30am |
Building Successful Vision Machines -The Practical Research and Engineering Work of the Integrator Dr. John M. Hinckley, Dunkley International, Inc. Beyond the world of tabletop demonstrations, successful machine vision is neither easy nor simple. In large part, this is due to the fact that the design of the vision machine is entirely dependent on the characteristics of the product to be inspected, the nature of its defects or non-conformities to be detected, the requirements and constraints imposed by the factory environment, and the degree of human operator involvement anticipated. It is the role of the machine vision integrator, when developing a custom system, to first, and foremost, research and understand these factors. This foundation then informs the integrator’s choice of technical approach to use in the vision machine. In addition to meeting the performance requirements, a viable technical approach must be both manufacturable and maintainable. Understanding of these factors, either from previous experience in similar situations or from feasibility studies, is essential for the provision of cost and delivery schedules which can be successfully met, providing a machine vision product with satisfactory performance. |
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| 11:30am- 12:15pm |
Catch Part Defects BEFORE They Happen Paul Hogendoorn, OES, Inc. If all variables in a process are stable and constant, the outcome of the process will remain stable and constant as well. The ‘variables’ in a process that might change and affect part quality could be the raw material, broken or worn tooling, machine deterioration, equipment failure, lack of lubrication, or even improper presentation of the raw material. If the ‘outcome’ is altered, then a variable in the process has to have changed. The task then becomes effectively monitoring the process in order to detect the critical changes (or variations) in that process. |
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| 12:15pm- 1:30pm |
Luncheon | ||
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| 1:30pm- 2:15pm |
Large Scale Surface Scanning Dave Maxham, Automated Precision Inc. Non-contact surface scanning is becoming more usable as a tool to generate 3-D information about parts, components, and objects. This presentation describes the development of a new innovative technology for non-contact surface scanning of very large (up to 80m) objects. Developed by Automated Precision Inc. and Steinbichler GmbH, Smart Scan uses a white light scanner combined with a laser tracker and six degree of freedom Smart Track Sensor to offer high resolution, high precision scans of extremely large surface areas in a fraction of the time compared to traditional methods. The two systems work together to allow quick and easy stitching of many images, assembling them into a single 3-D point cloud to virtually eliminate overlap errors or bending errors typically associated with large scans. |
Automatic Measurements With Flexible Programmable X-ray Image Evaluation Routines David Lehmann, GE Sensing & Inspection Technologies The diversity of quality requirements in manufacturing environments demands a flexible image processing tool. For automatic non-destructive measurements of internal features, such a tool is realized by Xe², a graphical development system for measurement scenarios in the x-ray image. Within this development environment the user can choose between a lot of different image processing algorithms, which can be combined with almost no limitation. The algorithms in use are for example edge detection, grayscale analysis, pattern matching or void detection. After using the image processing algorithms it is possible to run geometrical or statistical functions on the extracted features like the fit of geometric principles, data rows, Boolian operators, etc. |
Optical Non-Contact Surface Roughness Measurement David Rideout, Olympus America Inc. The field of surface metrology and roughness analysis has grown rapidly over the past few years, as engineers, scientists and technicians have realized that understanding surfaces is key for ensuring the performance and safety of manufactured products. As nanotechnology increases in importance, the use of microscopic surface metrology instruments must keep pace. The realm of surface metrology until recently was dominated by interferometers and contact profilometers, but as technologies advance there is a need for a more flexible and complete solution. The latest generation of laser confocal technology systems fills that need by providing direct surface roughness data, while offering backward compatibility to profilometers.
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| 2:15pm- 3:00pm |
Calibration and Testing of CMMs: An Update on the Latest Standards Jim Salsbury, Mitutoyo America Corporation Accuracy standards for coordinate measuring machines (CMMs) have significantly changed over the past year, and all users of CMMs need to understand how these changes will impact the calibration and purchase of any CMM. The ASME B89.4.1 has been withdrawn, and with its passing, so to goes the volumetric performance test, a.k.a. the ball bar test. The B89.4.1 has been replaced with ASME B89.4.10360.2-2008, which harmonizes the efforts of both U.S. and international experts. This new test method fully complies with the new ISO 10360-2:2009, which contains a number of important updates over its prior versions. As the CMM market has matured, so to have the testing methods; and in addition, the new standards provide a platform for expanding the same testing concepts to new CMM technology, such as vision-based instruments. This presentation will discuss the new standards, the key differences, the logic behind the changes, and the future direction of accuracy standards for CMMs. |
Management Confidence and Production Uncertainty Brian D. Bright, ATEQ This executive presentation will address the source of quality and production problems that are unknowingly being diluted as they progress up the management chain. The very best Quality, Manufacturing, Product and Six Sigma Engineering Managers are unable to uncover this problem because, according to the production data, the problem doesn’t exist. |
Five Good Reasons to Use Vision Software Thomas Nepstad, Cognex Industrial vision inspection is now essential in most production lines around the world. With the constant introduction of new vision technologies, it is hard to tell if your existing vision system is still the best solution for your current inspection demands. In this presentation, Thomas Nepstad will explore the benefits of PC-based inspection using vision software. Using vision software instead of integrated systems provides benefits including acquisition flexibility, powerful vision tools, scalable hardware, simple integration and lower cost. With application examples, tables and discussions, he will help you recognize the potential of vision software in factory automation and quality assurance. |
| 3:00pm- 3:30pm |
Afternoon Break | ||
| 3:30pm- 4:15pm |
Our Quality Journey to Baldrige - Malcolm Baldrige National Quality Award Winner Cathy Kuhn, Honeywell Federal Manufacturing & Technologies, LLC Honeywell Federal Manufacturing & Technologies (FM&T) received the Malcolm Baldrige Quality Award, the Nation’s Highest Honor for Performance Excellence in November 2009. As one of the nation’s most diverse low-volume, high reliability production facilities, Honeywell FM&T is at the heart of the National Nuclear Security Administration’s nuclear security enterprise providing high-tech production services to government agencies with low-volume, high-quality requirements while under contract to Department of Energy. This presentation will focus on Honeywell FM&T’s quality journey which led to receiving the Malcolm Baldrige National Quality Award. |
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| 4:15pm- 4:30pm | Closing Remarks & Raffle Prize Drawing Tom Williams, Quality Magazine |
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| 6:00pm- 10:00pm |
Dinner Reception | ||
| 9:00am- 1:00pm |
PLANT TOUR Lockheed Martin Facility Tour -Lockheed Martin Museum -Optics and Diamond Turning Lab -Precision Metrology/Inspection and Machining -General Machining area FMS system -Metrology/Calibration |
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