1. Business’ Impact on Metrology Author: Howard Zion NCSLI Orlando, FL 8/6/08 Section 6C Business’ Impact on Metrology Slide 1 of 31

2. Measurement Matters to Business: Overview – from a CSP’s perspective Part 1: Business’ Impact on Metrology – H. Zion How a customer’s requirements and decision criteria translate to a CSP’s practices and deliverables Part 2: Metrology’s Impact on Business Processes – J. Sims How calibration data helps a customer to quantify risk in their manufacturing and related processes Part 3: Metrology's Impact on Business Goals – P. Mistretta How calibration results ultimately affect the customer’s ability to achieve their business goals Business’ Impact on Metrology [2 / 31]

3. Product Design Manufacturing Process Specs Metrology Impact Engineering Design Specs Business’ Requirements Supplier’s Requirements What is the Link between Business and Metrology? 1 st Example: Business: Automotive Manufacturer Supplier: Machine shop specializing in axle manufacturing. Supplier’s Requirements Product Design Manufacturing Process Specs Engineering Design Specs Metrology Impact Business’ Requirements Business’ Impact on Metrology [3 / 31] 2 nd Example: Business: Plastics Manufacturer Supplier: Internal Machine shop specializing in plastics manufacturing.

4. Metrology Impact What happens to the manufacturing process if... ? Quality Issues Customer Service Issues Turn Time Accreditation / Traceability Limited CalDocumentation Issues Lab Assets Down Customer Approval Delays ≥4:1 TUR but PCS < 1 Shipping Damage <4:1 TUR Onsite Expectations Change Business’ Impact on Metrology [4 / 31] What is the Link between Business and Metrology?

5. Metrology Impact What happens to the business if... ? Quality Issues Customer Service Issues Typically causes unnecessary production delays May cause bad product which can lead to product recall Bad product = Increased Risk Increased Scrap/Waste Increased Cost Production delays = Increased Cost Delivery Delays to Client Loss of competitive advantage Manufacturing Process ImpactSupplier / Business Impact Business’ Impact on Metrology [5 / 31]

6. Metrology’s Impact on the Process [6 / 31] Session Topics Business’ Impact on Metrology Metrology Results: Technical Impact on Customer Process Metrology Practice Impact on Business Business’ Impact on Metrology Metrology Results: Technical Impact on Customer Process Metrology Practice Impact on Business Business’ Impact on Metrology Metrology Results: Technical Impact on Customer Process Metrology Practice Impact on Business Responsibility Communication Expectations How do these relate to business? –It is critical that any calibration service provider (CSP) take responsibility to understand their client’s needs and business requirements. –Likewise, it is critical that any instrument owner communicate their needs and business requirements to their service provider. –These two checks and balances will ensure an optimal calibration that meets both customer expectations and business requirements.

7. Agenda Business’ Impact on Metrology [7 / 31] Example One: Manufacturing an Axle –Manufacturing drives the measurement requirement –Testing methods for the manufacturing process –Go and No-Go Test Design –Calibration requirements for the process instruments Example Two: Hydraulic Cutting Machine –Manufacturing Process: Panel meter’s application in process measurement –Calibration requirements for the process instruments

8. Manufacturing Drives the Measurement Requirement 1.Process starts with selection of raw materials: 4150 grade steel is selected for this particular axle 2.Next step is to turn the raw material to the rough diameter required CNC machine is used for this process Business’ Impact on Metrology [8 / 31] Example One: Manufacturing an Axle Photos courtesy of www.usaxle.comwww.usaxle.com Per the design for the part, the axle’s rough diameter must be a certain dimension within an allowable tolerance to allow for additional cutting and grinding

9. Manufacturing Drives the Measurement Requirement 4.Hardening and Tempering give the steel its strength: This process realigns the atoms within the steel into a crystalline structure This also makes the steel structure more homogenous throughout, which minimizes wear and prevents breakage of the part Business’ Impact on Metrology [9 / 31] Photos courtesy of www.usaxle.comwww.usaxle.com Example One: Manufacturing an Axle

10. Manufacturing Drives the Measurement Requirement 4.Splining process cuts grooves along the ends of the axle: This process makes the part ready to fit into its mating part during assembly 5.Grinding process removes burrs and rough edges Business’ Impact on Metrology [10 / 31] Photos courtesy of www.usaxle.comwww.usaxle.com Example One: Manufacturing an Axle

11. Business’ Impact on Metrology [11 / 31] Photos courtesy of www.usaxle.comwww.usaxle.com Example One: Manufacturing an Axle Manufacturing Drives the Measurement Requirement 6.The final part must be tested prior to assembly

12. Business’ Impact on Metrology [12 / 31] Example One: Manufacturing an Axle Testing Methods for the Manufacturing Process Manufacturing Engineer needs a method of checking these completed axles The test limit of the axle diameter is 1.0000” +0/-0.0005” Which inspection method would best fit this application?

13. Business’ Impact on Metrology [13 / 31] Example One: Manufacturing an Axle Testing Methods for the Manufacturing Process The selection of the right instrument depends on the test limit (+0/- 0.0005”), the volume of testing required, and the cost of the instrument.

14. Testing Methods for the Manufacturing Process If a single test instrument is used, such as a caliper, then the accuracy of the caliper (±0.0005”), which is a bisymmetrical tolerance (equally ±), would be compared to the test limit (+0”/-0.0005”), which is a unilateral tolerance and would look like this: Note: TAR is not the best measure of this comparison, but is commonly used. TUR is a better measure and will be covered later in the presentation. Business’ Impact on Metrology [14 / 31] Example One: Manufacturing an Axle +0” / -0.0005” TAR = ±0.0005” _______________________________ (+0”) – (-0.0005”) = (+0.0005”) – (-0.0005”) __________ +0.0005” = +0.0010” ____ 0.5 = 1 or 0.5:1

15. Testing Methods for the Manufacturing Process Since there is a large volume of axles to be tested, the engineer considers a quick and inexpensive test using a set of Go/No-Go Rings Business’ Impact on Metrology [15 / 31] Example One: Manufacturing an Axle

16. [0.99950, 1.00000] Testing Methods for the Manufacturing Process Effectively, a Go/No-Go type of test splits the axle test into two parts: –The axle’s test accuracy is 1.0000” +0/-0.0005” which creates the tolerance limits: –The No-Go Ring Gage checks the axle’s lower limit with an accuracy of +60µ”/-0” –The Go Ring Gage checks the axle’s upper limit with an accuracy of +0”/-60µ” This method of testing is also excellent as it checks the fit, form, and function of the axle, which a direct diameter measuring instrument does not do [0.99950, 1.00000] Business’ Impact on Metrology [16 / 31] Example One: Manufacturing an Axle [0.99950, 0.99956] [0.99994, 1.00000]

17. Testing Methods for the Manufacturing Process –Again, the test result using an absolute reading device like a caliper yields a quantitative value for the axle and it compares a unilateral test limit (for the axle) to a bisymmetrical tolerance (for the caliper). –But with limit gages, t he Go/No-Go test splits that bisymmetrical tolerance into two unilateral tolerances for the upper limit and the lower limit of the axle and yields a Pass/Fail result rather than a quantitative result. –The ratio for this test using limit gages can then be calculated as follows: Business’ Impact on Metrology [17 / 31] Example One: Manufacturing an Axle +0” / -0.0005” TAR = (+0.00006”) – (-0.00006”) _______________________ = __________ +0.0005” +0.00012” ____ 4.2 = 1 or 4.2:1

18. Go and No-Go Test Design Go Test: –The class X Go gage has tolerance limits of +0” / -60µ” –The lower and upper limits are [0.99994”, 1.00000”] –Go limit gages are manufactured to their maximum material condition (MMC) and are allowed to wear to a least material condition (LMC; i.e., maximum hole diameter) before being replaced The MMC is 0.99994”, which is the smallest hole size (most material) The maximum diameter is the nominal value of the ring (in this case 1.00000”), which is the size to which the usage wear increases the ring diameter Business’ Impact on Metrology [18 / 31] Example One: Manufacturing an Axle

19. Go and No-Go Test Design (cont’d) Go Test: –At its onset, a new Go gage will reject a small amount of “good” parts whose diameter is near the upper limit of the axle test –As the Go gage wears under normal use, the number of “good” parts being rejected will diminish –Once the wear is great enough to exceed the upper limit of the Go gage, it will fail its calibration and be replaced; if the gage continues to be used beyond the upper limit, it will allow bad parts to be passed as it wears –Once replaced, the process of rejecting a small number of “good” parts begins again Business’ Impact on Metrology [19 / 31] Example One: Manufacturing an Axle

20. Go and No-Go Test Design No-Go Test: –The class X No-Go gage has tolerance limits of +60µ” / -0” –The lower and upper limits are [0.99950”, 0.99956”] –No-Go limit gages are manufactured to their maximum material condition (MMC) and are allowed to wear to a least material condition (LMC; i.e., maximum hole diameter) before being replaced The MMC is the nominal value of the ring (in this case 0.99950”), which is the smallest hole size (most material) The maximum diameter is the upper limit of the ring (0.99956”), which is the size to which the usage wear increases the ring diameter Since most parts will not be manufactured smaller than the lower limit of the axle test, parts do not usually fit through the No-Go gage, making these gages last longer than their Go counterpart Business’ Impact on Metrology [20 / 31] Example One: Manufacturing an Axle

21. Go and No-Go Test Design (cont’d) No-Go Test: –At its onset, a new No-Go gage will accept all “good” parts whose diameter is near the lower limit of the axle test, but that do not exceed this value –As the No-Go gage wears under normal use, it will begin to reject “good” parts that are near the lower test limit –Once the wear is great enough to exceed the upper limit of the No-Go gage, it will fail its calibration and be replaced; if the gage continues to be used beyond the upper limit, it will reject a larger and larger number of good parts as it wears –Once replaced, the process of accepting all “good” parts begins again Business’ Impact on Metrology [21 / 31] Example One: Manufacturing an Axle

22. Calibration Requirements for the Limit Gages –So the engineer orders the set of rings from an approved supplier and bases this quality process on the accuracy of these class X rings –The Original Equipment Manufacturer (OEM) states that these limit gages are manufactured and tested to ASME B89.1.6 –The OEM’s calibration certificate indicates a single value for the ring diameter and includes a statement of compliance indicating that the ring is In-Tolerance –The gage is used in the manufacturing process and comes due for recalibration –As with all gages in the plant, these limit gages are sent in to the company’s regular calibration service provider (CSP) with no communication of expectations for cal Business’ Impact on Metrology [22 / 31] Example One: Manufacturing an Axle

23. Calibration Requirements for the Limit Gages The CSP can see that the ring is marked with Class X and therefore knows the tolerances against which it must be calibrated But, what about ring gages that are not clearly marked? If the process requirement is not clearly documented, the user of the limit gages might inadvertently have them calibrated to the wrong class tolerance This elevates the risk of passing axles that should not have been allowed to pass; if calibrated to Class Y tolerances: Although this lower ratio may appear to be a problem, the real issue is that the limit gage is allowed to be used beyond the intended limit This means more good parts will be rejected or bad parts allowed to be accepted Business’ Impact on Metrology [23 / 31] Example One: Manufacturing an Axle +0” / -0.0005” TAR = (+0.00009”) – (-0.00009”) _______________________ = __________ +0.0005” +0.00018” ____ 2.8 = 1 or 2.8:1

24. Example One: Manufacturing an Axle Largest Diameter Shaft that will pass through the ring Most wear Least wear Calibration Requirements for the Limit Gages On another note, the reporting of a single diameter upon recalibration is not realistic, since ring gages do not wear evenly from normal use An out-of-round condition implies there are multiple diameters that should be reported: Which one is important to the process owner? Is a “Best Fit Approximation” the correct reporting of this error? The red dashed line in the figure indicates the largest axle that could pass through this ring, assuming the axle is perfectly round also Business’ Impact on Metrology [24 / 31]

25. Business’ Impact on Metrology [25 / 31] Example One: Manufacturing an Axle Largest Diameter Shaft that will pass through the ring Most wear Least wear Calibration Requirements for the Limit Gages ASME B89.1.6 checks for roundness only if the ring gage is a diameter master For limit gages, such as these, the B89 spec states that these “... shall be evaluated by criteria applicable to the intended use...” This underscores the importance of communication between the process owner and the CSP It is also mandatory under ISO 17025, section 4.4 Review of requests, tenders, and contracts, that the CSP understand and document their client’s expectation for calibration

26. Business’ Impact on Metrology [26 / 31] Example One: Manufacturing an Axle Largest Diameter Shaft that will pass through the ring Most wear Least wear Calibration Requirements for the Limit Gages The major diameter and minor diameter values that are reported with the calibration data will be evaluated in the next presentation to understand the effect on risk in the test acceptance process

27. Manufacturing Drives the Measurement Requirement 1.A hydraulic cutting machine is used to cut large and/or thick sheet materials, such as plastic, steel, etc. 2.The machine uses a panel meter to monitor the 4-20 mA current loop output of an embedded pressure transducer 3.The pressure transducer and the panel meter are calibrated regularly 4.A Fluke 715 Volt/mA Calibrator is used by the process owner as the standard in calibrating the panel meter Business’ Impact on Metrology [27 / 31] Example Two: Hydraulic Cutting Machine Photos courtesy of www.china-cutting machine.comwww.china-cutting machine.com

28. Manufacturing Drives the Measurement Requirement 5.The process owner submits the calibrator to their CSP with the assumption that it will be calibrated to the OEM’s accuracy specifications 6.In one part of the calibration, the CSP uses an Agilent 3458A DMM to check the current sourcing function. 7.The resulting Test Uncertainty Ratios (TUR) range from 2.9:1 to 3.8:1 throughout the current sourcing function. 8.These TURs are included with the certificate of calibration per the CSP’s quality policy. Business’ Impact on Metrology [28 / 31] Example Two: Hydraulic Cutting Machine Photos courtesy of www.china-cutting machine.comwww.china-cutting machine.com

29. Manufacturing Drives the Measurement Requirement 9.The CSP is accredited and failed to understand and document this client’s requirements under ISO 17025, section 4.4 10.The client’s SOP’s require that all calibrations meet a minimum 4:1 TUR 11.None of the test points in the current sourcing function met this requirement 12.Does the calibrator need to be resubmitted for calibration? The next presentation answers this question. Business’ Impact on Metrology [29 / 31] Example Two: Hydraulic Cutting Machine Photos courtesy of www.china-cutting machine.comwww.china-cutting machine.com

30. Business’ Impact on Metrology Metrology Results: Technical Impact on Customer Process Metrology Practice Impact on Business Summary Business’ Impact on Metrology Metrology Results: Technical Impact on Customer Process Metrology Practice Impact on Business Business’ Impact on Metrology Metrology Results: Technical Impact on Customer Process Metrology Practice Impact on Business Business’ Impact on Metrology [30 / 31] Responsibility Communication Expectations How do these relate to business? –It is critical that any calibration service provider (CSP) take responsibility to understand their client’s needs and business requirements. –Likewise, it is critical that any instrument owner communicate their needs and business requirements to their service provider. –These two checks and balances will ensure an optimal calibration that meets both customer expectations and business requirements.

31. Thank You Questions ? Business’ Impact on Metrology [31 / 31]