Abstract
Micron measurement of the manufactured part is an integral part of production process. This decides qualification of the manufactured part’s acceptance or rejection. First principle methods are well established to measure the manufactured parts with utmost certainty. In the advent of Industry 4.0 in the digital revolution era of manufacturing, an electronic measurement of various dimensional parameters is gaining prominence. The shortcomings of measurement by first principle methods such as written documents, inability to automate the analysis and hence cloud connectivity, etc., can be achieved with electronic gauging. In the proposed work, an electronic gauge with micron resolution and cloud connectivity is devised for measurement of outer diameter of a mass production component. The measured readings are validated using statistical methods for the Gauge Repeatability and Reproducibility (GRR). The electronic gauge registered greater stability in the key parameters of gauge capability such as Equipment Variation (EV), Appraiser Variation (AV), Part Variation (PV) and %GRR over its conventional measurement counterpart. The electronic gauge recorded %GRR of 7.81% against conventional gauge’s %GRR of 14.47%. This made the electronic gauge acceptable without any conditions for the measurement of a critical parameter in mass production environment. The paper extended the scope to record the measurement readings in cloud-enabled platform to make the measurement system ready in the context of Industry 4.0. The proposed model has been implemented and validated in a mass production set-up, engaged in manufacturing of precision auto components.
Highlights
Digitalization is the new revolution in the manufacturing world
This paper focused on the cloud connectivity of measurement system, which will strengthen the measurement systems with the following advantages: The designed gauge is implemented in an Indian Small and Medium Enterprise (SME) which is engaged in manufacture of precision automotive component in large volumes
The existing method was not enough capable and was conditionally acceptable as per the guidelines provided in Automotive Industry Action Group (AIAG) which was more than 10%
Summary
Digitalization is the new revolution in the manufacturing world. Manufacturing industry is compelled to shift towards digitalization to increase productivity, performance and. The gauge’s performance parameters such as repeatability and reproducibility are measured using statistical methods as framed and recommended by Automotive Industry Action Group (AIAG) 4th Edition [1]. The gauge capability is validated with reference to conventional measuring methods using statistically analyzed results. The LVDT-based dimension measurement data acquisition and monitoring system, exponentially increases the capability of handling, comparing, deriving decisions autonomously, which is a fundamental nature of Industry 4.0. The proposed work is a contribution towards making the measurement reading results in digital form, which is validated and proven by statistical methods of measurement system analysis and connected to cloud. “Literature Survey” carries literature survey covering importance of digital metrology, statistical methods for the gauge repeatability and reproducibility, importance of digitalization in Industry 4.0 era, guidelines derived by the generic models for implementation of cyber physical systems, etc.
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