360 sims - the power of large data for 3d metrology and process control
TRANSCRIPT
360 SIMS – The Power of Large Data Set in
Automated 3D Metrology & Process Control
By Tal Vagman, Director Product Strategy
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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
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Sampling (Traditional CMM) 100% Inspection
Sampling off-line vs. 100% Inspection in-line
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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
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Reduce variation
(dimensional volatility in production)Bring process to nominal or functional
(CAD or Virtual Master)
Process Control Motivation
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Product Quality Development & Monitoring
Upper reject limit
Upper spec limit
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Inspection Plan – Until today based on critical points only
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With 360 SIMS: Both Area & Critical Features Measurement
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Multi-Part Process Evaluation During Pre / Production
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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
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Dimensional Rules Management on Go / No go decisions
OK – Within tolerance
Trending – Near tolerance limit
Out of tolerance
Measurement Error
Rejected – Stop the line
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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
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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
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Production measurement results used for Part Inspection by
various Software (Customer, 3rd Party and Hexagon Metrology)
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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
•
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Process Control Life Cycle & Identifying Different Situations
Stabilization during
Launch / ramp up
Controlling a
stable processAdapting limits according
To production stability &
tolerance
Handling less stable
points
Non stable critical points
Temporary / limited
rejections Or reworks
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Point and Area based Process Control / Server Based
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Process Control Tools (Features and Dimensions)
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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
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From Fully Automated Station to User Intervention
Steady state Checking data
Visual inspection Analysis room
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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
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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
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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
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Back lights Assembly Area Detailed Study – Detailed AnalysisSpecial study alignment based on assembly features Cross section 2D analysis on back light area
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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
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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
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“Image of the day” reporting
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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
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Patented “Video-of-the-day” – Split Screen on different areas
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In Future – more actionable data into the video report
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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
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The Data Challenges
We create a lot of data and needs to be:
• Stored
• Distributed
• Managed
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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
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~50 Mgb per part
700 parts/day
35 Ggb per day
Saved time, 6 months ≈ 6.4 Tb
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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 !