For over 20 years, IST Precision has been a trusted partner for manufacturers seeking customized metrology systems and solutions.
The Challenge: The Hidden Cost of Reactive Quality Control
While some manufacturer’s view metrology equipment as an unnecessary upfront cost, neglecting proper quality control in the manufacturing environment can have far-reaching consequences. At IST Precision, we’ve witnessed firsthand how a lack of proper inspection allows faulty parts to slip through the cracks. Even seemingly minor issues like low manufacturing yields can have a major impact on production efficiency and profitability. In these scenarios, companies are often forced into reactive mode, scrambling to implement quality control measures after the fact.
This reactive approach isn’t just costly; it also exposes companies to potential safety risks and reputational damage. The ideal scenario is to be proactive with quality control, preventing problems before they occur. In the next section, we’ll explore a real-world example of how a custom metrology system helped a manufacturer address a costly yield issue, demonstrating the true value that goes beyond simple measurement.
Collaborative Development: From Concept to Completion
A recent project at IST Precision involved a customer facing inconsistent production yields at one of their manufacturing plants. The culprit was an assembly process that relied solely on a manually adjusted screw torque setting to ensure consistent deformation of a spring membrane element. Unfortunately, variations in friction and mechanical interfaces were causing inconsistencies in the spring element’s deformation.
IST Precision identified the Keyence LJ-X8000 series high-resolution laser line scanner as the ideal solution for this application. These scanners offer exceptional profile data making them well-suited for inspecting cavities and holes like the one in our customer’s assembly process. A key advantage of the LJ-X8000 series is its high-speed data capture, allowing for rapid inspections (under a second) with results reported directly on the HMI screen. In this case, the LJ-X8200 model was chosen due to its vertical resolution and sampling rate for the entire laser line.
Our team designed a system that mounted the laser line scanner on a servo Z axis stage for optimal focus distance, ensuring precise measurements within the cavity. The customer’s parts were placed on a custom-designed clamping fixture for easy positioning, and the entire system was built with the operator in mind.
This custom metrology system allowed the customer to directly measure the spring element, ensuring consistent deformation and leading to a dramatic improvement in production yields. The system was designed for simple operation and was successfully commissioned at the customer’s inspection lab.
Conclusion: Proactive Quality Control for Long-Term Success
By implementing IST Precision’s custom metrology solutions, manufacturers gain a powerful advantage. They can elevate their quality control processes, reduce production costs, and achieve consistent yields. This proactive approach to quality control empowers manufacturers to avoid costly problems and ensure long-term success.
While the system discussed here is a standalone solution, IST Precision’s expertise extends far beyond. We are highly experienced in integrating metrology systems seamlessly into automation lines. This capability allows for high-throughput, in-line inspections, further optimizing production efficiency and yield.
If you’re a manufacturer seeking to elevate your quality control processes and integrate them into your automation lines, IST Precision is the ideal partner. Our combined expertise in metrology and automation ensures a seamless and effective solution, tailored to your specific needs.
Mobile line scanner cart and custom fixtures