The manufacture of automotive body panels and other stamped parts requires high levels of measuring accuracy. Ogihara America, a Tier 1 supplier of body panels and assemblies, needed to meet higher quality standards and reduce inspection time. To achieve this, an automated 3-D white light digital measuring system using advanced non-contact gauging technology has been adopted. Ogihara America is the US subsidiary of the Japanese Ogihara Corporation. It has sourced the measuring system from CogniTens, part of the Hexagon Metrology group, which specialises in advanced 3D metrology systems that allow manufacturers to pinpoint where a physical part differs from its specifications, identify the cause of a problem and qualify tools, parts and assemblies for production.
Fully automated measuring
The two companies have an ongoing relationship, as Ogihara has already successfully implemented CogniTens’ portable Optigo measurement systems at its US facilities. A fully automated dimensional measurement system for automotive parts and assemblies was the logical next step for Ogihara. Based on Ogihara’s requirements for operational flexibility, CogniTens, together with its partner InspectionAir Gauge, delivered a fully automated and standardised OptiCell system for providing rapid dimensional results for closure subassemblies on multiple vehicle programmes. OptiCell’s set of measurement technologies provides reliable full-surface, edges, common features and cross-section measurements for multiple parts during pilot manufacturing and mass production stages.
An integrated approach
The OptiCell provides tight integration of sophisticated robotics technology and operator-machine interface as well as cell automation and control devices such as rotary tables and flexible holding fixtures. This integrated approach accommodates the maximum number of parts and assemblies, while minimising the costs associated with making changes and providing maintenance. Additionally, it allows parts and assemblies to be easily adapted to specific Geometric Dimensioning and Tolerancing (GD&T) requirements.
Ogihara installed its first OptiCell in mid-2007. Based on its automotive OEM customers’ requirements, it now has more than 50 different parts to measure as details and shipping units. OptiCell’s ease of use, rich metrology data set and location on the plant floor make it a valuable asset for the Ogihara launch and production teams. Ogihara’s unique process combines OptiCell’s white light measurement technology with fast and agile laser welding systems at Ogihara’s manufacturing facility. OptiCell provides Ogihara’s production staff with instant lineside data required to make comprehensive functional build adjustments as needed.
Streamlined production
Ogihara’s production facilities provide critical parts and assemblies to General Motors, Ford and Chrysler as well as to several Japanese plants across North America. All Ogihara facilities around the world share common processes for ensuring lean and streamlined operation. Common processes help Ogihara develop and manufacture more cost effectively while ensuring the best quality for the customer at all times.
“We were pleased with the performance of the CogniTens/ InspectionAir Gauge cell and decided to expand its use in our processes,” says Steve Peca, executive manager for quality assurance at Ogihara America. “We are realising fewer quality loops for the new production and assembly tooling and have them ready for production faster than ever before.”
Peca continues: “During launch phases OptiCell’s 3D measurement results makes it easy to reach a full understanding of our initial part quality and allows us to focus our quality support efforts to customers during launch team part reviews. Based on our experience, the OptiCell has paid for itself in about three months simply by eliminating hundreds of CMM inspection hours and iterative quality procedures.
” The OptiCell’s clean cell design and robust measurement technology allows easy operation directly within the assembly bay area on the production floor. Ogihara is already implementing its second OptiCell to support a new vehicle programme by a major North American OEM, to which Ogihara will be providing various sheet metal parts and sub-assemblies.
“Each cell that we provide to customers has been tuned based on lessons learned and is enhanced with best practices and latest technologies to offer Ogihara the very best shop floor measurement solution,” says Ray Sparnaay, InspectionAir gauge general manager. “We are now at the point where the modular design of these cells allows us to go from idea to concept to shop floor integrated cell in a fraction of the time required to build traditional fixtures. CogniTens continues to take a market driven approach to system and software development, which supports such a shift in process from traditional fixtures and probing to white light shop floor measurement.”