Team Leader of the Electroform Quality Control and Machining Department
Patrick graduated in 1999 as a CNC machinist and worked for 10 years in different fields, such as hydro-electricity for Alstom Power Canada, rail transport for Alstom Canada Transport, aeronautics for Pratt & Whitney Canada, and aerospace and telecommunications for a subcontractor of COMDEV. He also worked for NASA and several other companies. He is presently working in the field of plastic injection molds for automotive lighting at DBM Reflex and is completing a business administration certificate at the Université du Québec à Montréal.
Meeting Our Evolving Needs
With DBM Reflex since 2009, Patrick is team leader of the Electroform Quality Control and Machining Department; electroforms are the components that serve to produce reflectors that are found on vehicles. His team uses a wide variety of measurement devices to carry out inspections. His presentation will focus on solutions brought to a wide variety of inspection problems encountered in his quality control department over the last 10 years, such as:
• Best-fit calculations
• Management of inspection reports
• CMM CNC programming and collision detection
• Management of inspection files
• Training and employee development
He will also share the challenges that he sees in the near future.
DIMENSIONAL ENGINEERING, INC.
Andrew is a Project Engineer at Dimensional Engineering, Inc., has a B.S. in Mechanical Engineering from Ohio State, and has been a PolyWorks® user since 2011. He previously worked as a CAD Engineer for Sulzer Turbo Services. It was there he first started using PolyWorks® to reverse engineer and inspect turbomachinery components. In 2014, he joined Dimensional Engineering and has since served a variety of clients including ExxonMobil, GE, and Diamond Offshore. Most recently, he has been part of a metrology team supporting General Motors during the launches of their new, full-sized trucks and SUVs.
Reducing Modular LNG Plant Installation Time with PolyWorks® & Laser Trackers
Current modular build installation methods are extremely time consuming and prone to alignment errors, costly reworks, and require multiple field fits. These traditional approaches require skilled teams of pipe fitters, welders, and millwrights using brute force to assemble bolted connections. Tape measures, bubble levels, and come-alongs rarely provide the required precision to meet engineering tolerances.
Using PolyWorks®, FARO laser trackers and arms, Dimensional Engineering provided Baker Hughes with a more accurate and streamlined process. By inspecting individual modules, their interconnecting piping, and creating virtual assemblies in PolyWorks|Inspector™, we were able to identify and repair fabrication errors before the modules were delivered to the site owner. This proactive approach helped reduced the average install time of critical-path modules from three months to three weeks.
Assistant Manager, Prototype Quality and Technology Department
HONDA R&D AMERICAS, INC.
BIOGRAPHY GLENN HILL
Glenn started his career at Honda R&D Americas, Inc. in April 2002, working in supplier quality. He had experience with CMMs from past jobs and in 2003 was involved with purchasing a laser scanner for part inspection. It was at that time that Glenn first learned to use the PolyWorks® Metrology Suite; he has been using it for approximately 16 years now. His current position is Assistant Manager in Honda R&D’s Prototype Quality and Technology Department. Glenn has an Associate’s Degree in Plastics Engineering from Shawnee State University and a Bachelor’s Degree in Technology from Kent State University.
Specialist, Prototype Quality and Technology Department
HONDA R&D AMERICAS, INC.
BIOGRAPHY PAUL JEWELL
Paul has been in the measurement field for over 30 years. During this time, he has worked in various industries, from machine shops to foundries and composites, using various kinds of measurement equipment and software. Paul started work at his current position in the Prototype Quality and Testing Department (PQT) at Honda R&D Americas, Inc. in October 2007. As a Specialist in this department, he gets the chance to inspect parts for everything Honda makes. In the morning, it could be a part for a lawn mower or motorcycle, and in the afternoon, it could be a part for an automobile or the Honda Jet.
Using PolyWorks® Across Multiple Hardware Platforms at Honda R&D Americas, Inc.
Part inspection, in an automotive R&D environment, is usually much different than part inspection in traditional manufacturing. Typically, in mass production, part inspection involves checking the same part, day after day, year after year, until that product’s lifecycle is over. Furthermore, even if you’re manufacturing multiple different part numbers, it’s not uncommon for those parts to be roughly the same size or shape. For us, it’s quite the opposite. Checking multiples of the same part may mean checking two or three of them and then we’re on to something else. We may be asked to scan a complete vehicle in the morning and then scan a pair of sunglasses in the afternoon, or anything in between. To accommodate the varied scanning requests that we receive, we have a variety of different equipment from different manufacturers. Our discussion today will focus on the advantage of having a common software platform for part analysis on equipment supplied by a variety of different manufacturers.
Associate Manager - Metrology
Based in Reno, Nevada, working at Tesla Gigafactory 1 as Manager in Metrology, Mathieu has 11 years of experience in 3D metrology, GD&T, reverse engineering, and tool design. Half of his career was spent in consulting services, which exposed him to industries all over the world. With 8 years’ experience in PolyWorks, his familiarity spans every module, from reverse engineering to probing, bringing an expert knowledge of GD&T to accurately perform dimensional analyses. His current endeavor at Tesla had him working in Fremont for a year and a half before moving to Gigafactory 1 (GF1) as a metrology engineer. After 1 year at GF1, he became Manager of the Metrology Department.
Streamlining Metrology Lab Operations by Using a Universal Metrology Platform
At Tesla Gigafactory, we built up a team of Metrology technicians and engineers from 6 employees to a group of 45 in less than a year. They run 7 different pieces of equipment on 4 different software. At this point, it becomes a necessity to search for a universal metrology platform for the long-term success of the team. On-demand investigations on the production line with a laser tracker, regular in-process inspection on a CMM, and supplier correlation studies on portable arms, all reporting on one metrology platform, will greatly improve the interpretation and analysis of reports.
This presentation will demonstrate how using one metrology platform can help streamline metrology operations and greatly benefit user training, while promoting team collaboration with team members who run other pieces of equipment.
Associate Technical Fellow
Michael Rounds is an Associate Technical Fellow recognized across the Boeing Enterprise and industry as an expert in large scale metrology, its integration and automation of production systems used to increase spatial awareness, reduce cost, and manufacturing flow. His influence and work in metrology system automation has spanned across all Commercial Airplane Programs and into Boeing Defense Space and Security (BDS). The importance of this technical field set coupled with his demonstrated performance has been acknowledged by the awarding of “Engineer of the Year” in 2015, as well as “Engineering Team of the Year” for 2015 and again in 2018.
PolyWorks Analysis flow and processing reduction through the use of Automation
Aerospace industry scale with exacting spatial tolerance requirements has produced an environment for unforgiving precision; with airlines and passengers demanding ever increasing features and efficiencies unheard of in previous generations of products. To answer that call Metrology has evolved from the investigational root cause analysis tool to quickly becoming the vital production system pulse taker for the modern aerospace manufacturing system. Automation also has evolved from case specific grounds for justification into a comprehensive baseline for efficient holistic production system sensoring. Partnering with InnovMetric PolyWorks has allowed Boeing Production systems to develop specialized integration and automated solutions through utilization of the Software Development Kit (SDK). Customization of interfaces, with specific task executions has allowed Boeing to develop stronger metrology performance metrics for efficiency, user error reduction, with consistent predictable output uniformity. Newer features and continued development of PolyWorks has allowed Boeing to take advantage of automated parallel and batch processing.
Applications Engineer Sr.
LOCKHEED MARTIN AERONAUTICS
After completing an undergraduate degree in Aerospace Engineering, I joined Hexagon Manufacturing Intelligence, a metrology solutions company as an applications engineer. My role involved training customers, developing custom metrology solutions and advising as to which systems would be a best fit for specific applications. During my years at Hexagon, I spent a significant amount of time working with Lockheed Martin Aeronautics to develop custom solutions for their metrology needs. I eventually accepted a position as an applications engineer with their Manufacturing Technology group and currently work on all aspects of applying metrology systems in order to improve current processes.
New Capability Creation and Analysis Automation Through PolyWorks® Expandability Tools
In the aerospace industry, part geometries can range from simple, prismatic featured-based components to complex, organic, and often unique geometries. PolyWorks has a proven record of providing users with measurement tools that simplify inspection processes, however, these distinctive geometries often require custom measurement tools to be developed to interrogate the quality of the work performed. This presentation will discuss how Lockheed Martin has used the expandability tools, such as macro scripting and the software development kit (SDK), to create new capabilities and automate analysis processes. Specifically, the applications of coatings thickness verification and seam validation will be explored.
Director of the Robotics and Automation Laboratory at the National Institute for Aviation Research (NIAR)
WICHITA STATE UNIVERSITY
As Director of the Robotics and Automation Laboratory at the National Institute for Aviation Research (NIAR) at Wichita State University, Brian Brown focuses on industry-driven projects that lead to immediate implementation in the production line, increasing productivity and product quality. Leveraging a combination of modern industrial and collaborative robotics, Brown and his staff of full-time engineers and student lab technicians can quickly evaluate manufacturing processes and implement a wide range of effective solutions. Brown has worked at NIAR-WSU since 2002 and has a B.S. in Aerospace Engineering from Wichita State University.
Enhancing Efficiency of Metrology with Automation
Automation can take many forms in today’s world. This session will look at how WSU-NIAR uses robotics with PolyWorks to automate simple through complex metrology tasks to make fast and efficient inspection work.