“Since using the EquatorTM, we have never produced an unqualified part and our part production costs have been reduced by 27%â€
Process control using the Equator
The company's product quality and quality assurance are the key to successful contract wins. Maintaining product quality will also significantly increase the likelihood that customers will continue to repeat purchases in the future. High-Tech Engineering is a precision engineering company based in Dunstable, Bedfordshire, England, which has always focused on the quality of its products. Now with the newly added Renishaw Equator, the company not only achieves 100% workpiece inspection and zero scrap rate, but also cuts the operator's demand by half and parts production costs by 27%.
Founded in 1985 by company general manager Steve Tickner, High-Tech Engineering has a reputation in the racing industry for providing quality parts for many years. Since its inception into the aerospace industry, the company has been recognized by a number of key companies, including becoming the preferred supplier of Rolls-Royce and BAE Systems.
Recently, High-Tech won a contract to produce precision turning and milling titanium parts for a large aerospace customer. Taking into account the characteristics of this part, High-Tech needs to perform 100% part inspection in accordance with the contract. Steve Tickner explains: “We knew from the outset that we needed to find a test method that would not only meet the cycle time requirements of part production, but also be a cost-effective solution. Existing coordinate measuring machines are no longer able to meet this requirement. We can't run the risk of bottlenecks in production. We know that we need another CMM or other device that provides the required measurement function. It is the reason that led us to find the Renishaw Equator."
Buy Equator
Steve learned about the Equator comparison instrument through a simple internet search. After some research and meeting with representatives of Renishaw, High-Tech was impressed with the function of the Equator and was very satisfied with the overall price of the equipment.
When it comes to High-Tech's reason for purchasing the Renishaw Equator, Steve said: "Our workshop space is very valuable. In the space reserved for the equipment, we need to deploy a faster, more efficient Technology. This means that the use of a CMM that requires a dedicated temperature control environment will take up a considerable amount of space and is therefore not economical. The Equator is a compact device that is perfect for us. In addition, its other great advantage is that it is not sensitive to heat changes and does not require a gas source, which means that we do not need to spend extra time, money and effort to build a temperature control room or arrange pipes."
High-Tech currently performs 100% inspection of complex aerospace parts using the Renishaw Equator. Its detection method is to compare the workpiece with the corresponding standard parts, and all the characteristic measurements can be completed in one operation, and the parts are immediately qualified, and the part size deviation report is provided.
The integrated measurement time is half of the existing CMM
The Equator is used to measure approximately 150 features, including a large number of bores, part thickness and shape measurements for parts, with a typical tolerance of ±25 μm. The Equator can perform these measurements in less than 10 minutes, which is well suited to the production requirements and the measurement time is much less than the processing time. Compared to Coordinate Measuring Machines using High-Tech, the cycle time to run the Equator Detector program is approximately 50% shorter.
Process control performed by the machine operator
High-Tech continuously produces 24 hours a day, taking a five-day, two-shift work system. During production, the Equator is operated by a number of operators of different skill levels. Previously, High-Tech Engineering relied on coordinate measuring machines installed in temperature-controlled quality control rooms away from machine tools. The use of a CMM to perform this latest task requires two operators, first the operator who machines the part, and secondly the operator with the expertise to operate the CMM. After replacing the CMM with the Equator, the newly trained operator can “zero†the Equator with the certified workpiece size approved by the QC and then set the accuracy of the subsequent measurements. In this way, the operator who processes the workpiece can also measure the part, thus reducing the overall operating time required by half.
Flexible and future-oriented
The Equator is fully programmable and can be used for a wide range of workpiece measurements, which means High-Tech Engineering can perform highly repetitive and fast automated inspection processes for multiple contracts at the same time, thus significantly reducing labor costs.
Easy to use - just push the button
When it comes to ease of use, Mr. Tickner pointed out: “Equator can be used by all operators. It is really easy to use; just load the workpiece and press the button. It greatly simplifies the process and reduces manpower. Demand, which in turn helps us achieve a quick return on investment."
Now, High-Tech has successfully reduced the processing cost of aerospace parts by 27% using the Equator. This really enhances the company's product competitiveness, ensuring that it can produce high-quality parts of the same precision, while bringing higher value to customers. By implementing these types of solutions and continually striving to improve its manufacturing processes, High-Tech has become the first company in the UK to win the SC21 Silver Award six times in a row. The award recognizes outstanding companies in the aerospace and defense industry in the UK with excellent product quality and guaranteed supply capacity. The requirement for the Silver Award is that the performance of parts delivered by the company for all customers must remain above 95%, and the part qualification rate must remain above 99.5%.
Mr. Tickner explained: “Since using the Equator, we have never produced an unqualified part. The operator can control the entire process with the Equator. They only need to view the Process Monitor of the Equator software. The process monitor screen, which lists all the features being measured. There is a small strip next to the feature name. When the size or position of each feature begins to drift, it will change from green to amber and finally to red. The operator knows Corresponding to each feature of the machine tool, it is therefore possible to take corrective action and adjust the process from time to time to ensure that the part is back into the tolerance range. When we perform 100% inspection, the chance of defective parts becomes very small." He continued "We also use these measurements to test different types of tools and find the type of tool that gives us the best efficiency - which will help us save more money in the future."
Prospects
Following the success of this processing unit, Mr. Tickner plans to apply the Equator to future production units to assist with other projects that will begin. He concluded: “If you find a device that can help you make qualified parts, reduce manpower, reduce total cost, and be affordable, this is a successful solution. All of these benefits will benefit our customers. They will also learn that they have the best quality products at the most affordable price."
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