What is a “Metrologist” anyway?Steven StahleyDir. Measurement Excellence

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Metrologist Defined…Wikipedia

Performs Metrology work involving precision measurement and comparison of physical quantities such as mass, length, time, force, speed, voltage and current. They calibrate precision equipment which measures these physical units. They may also certify that outside standards of such quantities as mass and volume are correct.

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Metrologist Defined…Agilent

Develops and evaluates calibration systems that measure characteristics of objects, substances, or phenomena, such as length, mass, time, temperature, electric current, luminous intensity and derived units of physical or chemical measure. Identifies magnitude of error sources contributing to uncertainty of results to determine reliability of measurement process in quantitative terms. ..Directs engineering, quality and laboratory personnel in design, manufacture, evaluation and calibration of measurement standards, instruments and test systems to insure selection of approved instrumentation. …

Cummins Confidential

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The Metrologist Role

But…do you have to have someone titled a Metrologist to do this work?

Or

Will someone with the right skills do?

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Paradigm Shift

Focus less on developing Metrologist and more on developing Metrology skills…

At Cummins Metrology skills can be utilized through out our manufacturing and business processes.

The most effective way to improve our processes is to get the right skills into the hands closest to the process.

In our plants we would rather have the manufacturing associates, technicians, engineers etc have the Metrology skills related to what they are doing then depend on one Metrologist to try to provide those skills.

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6 Sigma Project - Objective and Deliverables Decrease the educational gap in Metrology to

increase the percentage of qualified employees (exempt and non-exempt) in the manufacturing and engineering entities.

Qualifiers– Technical skills where focused on Dimensional

Metrology, as Cummins processes are dependent on length.

– Areas of focus• Manufacturing• Product development• Service

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6 Sigma Project - Objective and Deliverables Deliverables:

– Consolidated Skill Set (specifically in measurement systems) required for technicians and engineers

– Educational Gap Analysis for IUPUC, Ivy Tech, and local high schools in the subject of metrology for technical fields

– Curriculum Improvements for IUPUC and Ivy Tech and local high schools

– Resources Identified to support Curriculum Improvements for IUPUC/IVY Tech (Professor qualifications, text books, etc.)

– Utilization Plan for AMCE (Advanced Manufacturing Center of Excellence)

– Generic template to identify educational gap in other disciplines

How do we get there?

Compile master skill set in metrology for engineers and technicians

Review current university/HS curriculum and perform a gap analysis

Recommend revisions to the curriculum that satisfy the skill set needed to do the job.

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Stakeholder List

Identified all groups within Cummins that use metrology skills– Quality Engineering– Product Engineering– Manufacturing Engineering– Thermal Sciences– Laboratory Operations– Materials Engineering– Engine Emissions Testing Group– Service

Over 140 stakeholders were chosen from these groups to survey

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Voice of the Customer Survey

Customer Information– Position– Education/level– School attended– How should Metrology skills be delivered?

• University• M&TE OEM• Internal• Professional organiztion

– If Metrology courses where available locally would you be willing to take them?

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Voice of the Customer Survey

Skills List– 37 Metrology related skills where identified– Each skill has an associated definition– Each skill has associated levels 0 – Unaware to 4 – Expert– Please list your current skill level and what skill level you

should be at for you role.

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And the survey says…

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– Measurement Data Analysis - BOTH – Geometric Dimensioning &Tolerance – BOTH – Measurement Uncertainty Analysis - BOTH– Dimensional Hand Tool – BOTH – Lab Operations – BOTH – Calibration Procedures – BOTH – Lab Requirements of ISO TS 16949 – Managers/Engineers only– ISO/IEC 17205 – Managers/Engineers only– Lab Measures – BOTH – Print Reading – BOTH – Flow Measurement - BOTH– R&R Studies – BOTH – Surface Texture Measurement – BOTH – Lab Environment – BOTH – Cylindrical Form Measurements – BOTH

Top 15 Skills utilized by Managers/Engineers or Technicians or both:

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Training Results

Note: Most of stakeholders that chose “Cummins Internal Training” are open to non-credit offerings by the universities.

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Note: 16 stakeholders did not want to go back to school or attend training mainly due to the fact that their job does not

use very many metrology skills, the basics are learned on the job.

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Lessons Learned

Voice of the Customer Survey– When surveying a manager ask if they are answering as a

manager or an individual contributor – When asking what type of training they would be willing to

take to attain the skill, ask length as well as source

Evaluating the School Curriculums– Assure the schools clearly understand the skill definitions– Talk to all of the schools initially, then plan an individual

session with each.

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Next Steps - Phase 2

Looking beyond Columbus Indiana across facilities and the local colleges that support our plants

Expand the skills set to include more non-dimensional skills

Further refine the skill definitions and skill levels of the original list based on VoC and school feedback