Case Studies

PRECISION PLUG GAUGE CALIBRATION

REDUCING THE COST OF QUALITY WITH NON-CONTACT METROLOGY

All precision manufacturing Quality Management Systems (QMS) depend on accurate gauge calibration and verification. A failure to precisely manage and maintain metrology equipment creates a multitude of problems, including RMAs (Return Merchandise Authorizations) and worse, loss of customer confidence for future orders.

Large-scale manufacturers often address this challenge with dedicated calibration personnel or third-party calibration services. This is a time-consuming operation and susceptible to serious consequences if inconsistencies arise. Cost of quality typically skyrockets here, and quickly distinguishes the average manufacturing facility from the exceptional.

As a Tier 1 OEM component supplier, DGW has substantially reduced the time and risks associated with typical plug gauge calibration by using the Keyence IM-7000 Instant Measurement System. This recent addition to our manufacturing floor boasts 0.5-micron accuracy, with instant results stored directly to our Zeiss database, Piweb.

UNLOCKING BIG DATA VALUE WITH CUTTING-EDGE SPC

ADVANCED SPC SIGNIFICANTLY INCREASES PROCESS AND QS EFFICIENCY

Effective process control defines the ongoing success of any precision manufacturing operation. At DGW cutting-edge QDM (Quality Data Management) tools optimize and drive our internal workflow and QS. These tools enable us to add real value to customer projects with enhanced reporting that save time, costs and help us meet demanding lead times on complex projects.

Our inspection systems are dynamic and based on process controls, increasing our efficiency without sacrificing quality. DGW has transformed into a company that no longer finds non-conformance, but uses SPC as a predictive model to identify trends that would exceed tolerance and correct beforehand.

Printed CMM Fixtures To Reduce Cost

USING ADDITIVE MANUFACTURING TECHNOLOGY TO STREAMLINE QC COMPLEXITY

Managing complexity and cost is typically handled with clever estimating, but at DGW we reduce our customers’ total cost by infusing our process with technology. This approach allows customers to streamline their own internal workflows, especially in the critical QC process.

The CMM (Coordinate Measurement Machine) is one of the most powerful tools in manufacturing and quality control, but in a high mix situation reliable CMM workholdings can be difficult and costly to source. This becomes doubly problematic as part complexity increases.

DGW optimizes customers’ QC and CMM operations by providing duplicate fixtures for each production part using our Stratasys Fortus 3D Printer. This saves time by following a lean, reproducible QC process, and avoids costly bottlenecks
with valuable CMM resources.