This Case Studies Special Advertising Section features manufacturing companies with real-world challenges using quality equipment, software and services to solve their problems and improve their processes. These problemsolving stories describe myriad manufacturing challenges and how the correct application of a supplier’s product or service made the difference, providing quantitative benefits to quality and manufacturing issues. The suppliers in this special section present these real-world problems and solutions to help NDT Magazine subscribers who may have similar experiences. MENNIE MACHINE COMPANY: A VISION FOR QUALITY Borescopic visual inspection is a key component of Mennie Machine Company’s quality procedures. For some assignments, borescopic inspection is conducted in the traditional way, in conjunction with various methods of thermal and manual de-burring. However, industrywide, borescopes are increasingly being connected to video cameras to allow on-screen viewing of live borescopic Inspections, as well as the capture of video footage and still photos. Knowing this, Mennie Machine Company has taken borescopic visual inspection to a whole new level with its custom designed robotic inspection cells.They are fully automated, robot load, robot unload, cell inspection. Quality Manager, Kyle Goetsch said, “We basically developed a database of known good and bad product. Using video cameras attached to 8 different Hawkeye Borescopes (www.gradientlens. com), inspection images can be captured inside virtually any machined part. Inside one fuel system part alone, we capture, 24 different images using the Hawkeye Borescopes attached to cameras.Those images are then displayed, stored, and compared to reference images, on a computer and monitor outside the manufacturing cell’s cage. “In putting this robotics system together, and in visual inspection stations around the shop, we tested a number of different borescopes. Hawkeyes are clearly the best for our needs, with regard to magnification, craftsmanship and cost. Most important, we haven’t found anything that can match them for adequate lighting at the point of inspection” Goetsch said. Gradient Lens Corporation www.gradientlens.com 800-536-0790 email@example.com HIGH TEMPERATURE PHASED ARRAY SOLUTION FROM ECLIPSE SCIENTIFIC ESTempMaster is a high temperature phased array inspection solution package from Eclipse Scientific, designed to address the requirements of corrosion and weld inspections at elevated temperatures.With the ability to scan at high temperatures using an encoded motorized ultrasonic scanner, the operator can spend minimum time in direct contact with components thereby increasing safety, scan quality and repeatability. In addition, production does not have to be shut down which increases the efficiency of all routine maintenance and emergency Inspections. TempMaster is available in two different temperature range packages: Temp- Master Gold Series is designed to operate up to 150°C (302°F) and TempMaster Black Series is designed to operate up to 350°C (662°F). Several wedge options are available to accommodate the various wall thicknesses and curved surfaces. To complement TempMaster, Eclipse offers two powerful software solutions for high temperature inspections: ESBeam- Tool allows for easy design and simulation of an inspection and ESInspectionBank provides effective process management and secure control of scan data, from acquisition to analysis and reporting. For more information contact Eclipse Scientific at 519-886-6717 or email firstname.lastname@example.org TÜV Rheinland’s NDT Inspection Services Result in Improved Product Quality and Satisfied Customers for Eagle Precision Cast Parts Located in Muskegon, Michigan, Eagle Precision Cast Parts manufactures highquality investment castings. Holding tolerances Of +/- .005 per inch, along with maintaining a surface finish of 125 RMS, results in the reduction of machining costs, creating savings for many of Eagle’s customers. Precision and purity are of the utmost importance for Eagle Precision as the slightest deviation would result in excessive re-work costs and high percentages of returned castings. To achieve the best possible results, Eagle Precision has been using TÜV Rheinland Industrial Solutions’ Magnetic Particle and Ultrasonic inspections and Radiography testing for over eight years.Applying extensive experience in developing non-destructive testing and examination (NDT) laboratory programs, TÜV Rheinland ensures that the product complies with industry And company standards and meets Eagle’s economic and delivery requirements. The NDT services has helped Eagle Precision provide good-quality, certified product to the customer without a large investment in testing equipment and personnel at the foundry facility. TÜV Rheinland’s inspectors determine any potential issues before they can affect Eagle’s customers, and that has allowed the foundry to make improvements to its designs and processes to eliminate problems right away. Eagle continues using TÜV Rheinland’s services because NDT inspections have consistently improved Eagle’s product quality, resulting in satisfied customers. To learn more about TÜV Rheinland Industrial Solutions, visit www.tuvris.com or call 616-891-3570. Laserweld Quality Verified Inline at Production Speeds by New Ultrasonic Inspection System To verify the integrity of laserwelds in automobile transmission gear assemblies in high speed welding production lines, only a few samples can be sectioned periodically, leaving all the other assemblies untested. Working closely with international automobile parts manufacturers for many Years, and in response to their requests, Andec Mfg. Ltd. Has developed, and installed, its non-destructive Ultrasonic Laserweld Inspection Technology (ULIT) systems, to provide inspection of all assemblies in a line, at production speeds. In the ULIT systems the laser welded gear assembly is automatically placed on a self locating inspection fixture, submerged in a rust inhibited liquid to couple an Ultrasonic sound beam into the part, while it is rotated in front of a special custom made transducer assembly. The sound beam passes through a properly fused weld but is reflected from defects around the weld, such as lack of fusion or penetration, voids or shrinkage cracks, or a displaced weld or misaligned assembly. The ULIT system computer interprets these signals and displays them on a multicolour circle showing the location and size Of defects around the weld. It also computes the percentage of the total weld area which these defects represent, and displays that in a numeric readout, as shown. All of the assemblies are inspected at production speeds, with automatic acceptance and rejection determined by the size of individual defects, the total number of small defects, or the percentage of the total weld area which all defects represent. Andec products are described in their advertisement on page no. 10NDT Different Densities? Unreliable Measurements? Elcometer introduces the CG100 ABDL Ultrasonic Thickness Gauge to Plastic Manufacturer Francis Ward, specialises in the manufacture of plastic reusable intermediate bulk containers (IBCs) and drums for the storage and transport of hazardous and non hazardous liquids and solids, used in chemical distribution, pharmaceutical processing, food processing, and precious materials storage. Plastic containers need to meet Minimum wall thickness standards.As different densities of plastics are used for different types of products, they required an inspection gauge to measure the different densities accurately. Previous inspection equipment led to high failure rates with products rejected by their customer’s quality department for not meeting minimum wall thickness standards. Elcometer introduced the CG100 ABDL Ultrasonic Thickness Gauge with 1mHz ½” diameter transducer to Francis Ward to quickly and accurately measure the wall thickness of their plastic containers. To ensure Francis Ward manufactured plastic containers to their customer’s exact specification, Elcometer visited Francis Ward’s customer to compare and validate Measurements of the Elcometer CG100 to their inhouse ultrasonic inspection equipment. Jason Hinch, Francis Ward’s Operation Manager said, “Elcometer provided full technical training and support to our operatives, complete with easy to use guides to help us produce our own work instruction and procedures, ensuring a 100% pass rate by our customer’s quality inspection team”. For more information please contact Elcometer or visit our website www.elcometerNDT.com
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