This project was not quite on the scale of "Houston, we have a problem," but it required careful analysis nonetheless. We were presented with a new product development opportunity for an industrial hydraulics customer. Due to its application, the product had strict bore size requirements, which demands accurate measurements and precision machining. Initially, however, the factory was unable to generate consistent bore diameter results without adding additional machining processes and increasing manufacturing costs. Although the bore was being machined by capable CNC equipment to customer specifications using 2D CAD drawings, adjustments to the machining program were not consistently translating to the inspection data. CAB immediately performed R&R studies on the bore gauges to verify if the collected data was accurate. The gauge R&R study failed and revealed one gauge was unable to consistently provide accurate results. Once the gauge was replaced and passed R&R, a CPK capability study was then performed to justify/verify machining adjustments and ensure the machining process was capable of providing consistent results. The CPK study revealed passing results, and the project was ultimately successful due to the studies performed by CAB. And if necessary, we could have gone on to use our tool life analysis and CNC programming of cutter compensation in pursuit of a solution. This entire process took us only four days, much to the relief of our customer in Temple, TX.
Sometimes when all you have is a hammer, everything looks like a nail. We have more than a hammer, and we have the experience and versatility to realize that everything is not a nail. Our gage repeatability and reproducibility analysis put this project back on its rails, and we can deliver the same skills for you. Contact CAB Worldwide for further information.