Please see below some of EPMC speaker bio’s and presentation abstracts.
Red Bull Racing: Pushing the boundaries with metrology in Formula 1
Formula 1 is a sport of the finest margins. Every season the rules change, every circuit has its own demands and every millisecond saved could be the difference between winning and losing. The cars are a complex combination of around 100 000 components and perfecting each part is essential to providing speed on track and confidence in safety. Motorsport is an innovator and proving ground for the automotive industry and the development speed in F1 is unrivalled. This session will give an insight into the quality department at a top racing team, exploring how Red Bull Racing uses metrology to take new parts from a computer screen in the factory to a racing car on track.
Chris Charnley is the Quality Manager at Red Bull Technology, his vast engineering experience has been gained by getting his hands dirty as well as Senior Managerial positions. He has previously worked in the automotive business at Borg Warner for 24 years, where he was Lean Six Sigma Black Belt and also a Manufacturing Consultant for the Worldwide Turbocharger division, where he worked on major projects to deliver World Class Manufacturing.
His role at Red Bull Technology has many challenges and rewards. Chris has been with Red Bull Racing and Red Bull Technology from the beginning in 2004, and has seen and managed growth in technology as well as with the quality team. The Quality department covers many areas, including Metrology, Composite materials and also the NDT functions, not only at the facility in Milton Keynes UK, but also at every race and test. Red Bull Technology have won eight World Championship Titles in its short history, and they are looking for many more!
Paul Bulman, Director, Manchester Metrology
Paul Bulman is the director of Manchester Metrology Ltd. Paul Has worked all his life as a toolmaker for several large companies manufacturing jigs and fixtures for some key clients such as Rolls Royce and Airbus to name a few. After an opportunity arose at Faro, Paul moved over to life as an application engineer; then onto a sales role at Faro UK. After 3 good years at Faro Paul sensed there was an opening in the market for a subcontract measuring service and people needing to hire the equipment due to the cost factor to purchase new. Paul set up Manchester Metrology LTD 9 years ago and now has 14 members of staff and over 85 pieces of metrology hardware from several manufacturers including Faro, Leica and Hexagon. Paul’s company offers subcontract measuring services, training and hiring of all portable metrology equipment with all the latest software available on the market in the UK and Europe. This has taken them to many places including La Palma, Kazakhstan, Korea, Kentucky, Minnesota and many more places. The Company has seen a 65% increase in turn over and staffing levels year on year for the past 4 years and continues to grow with major investment totalling £700,000.00 alone this year and £500,000.00 last year. Pauls’ persistent hard work has evidently payed off and he continues to prove this daily.
Presentation: Portable metrology in the building industry.
Paul will look at large scale metrology used in the building industry and large scale metrology needed to help in building problems. In particular he will talk about the Bloomberg London project were he used the arm and the laser tracker and the Faro focus all on one project.
Dr Jody Muelaner, Research Fellow, University of Bath
Dr Jody Muelaner’s 20 year engineering career began in machine design, working on everything from medical devices to saw mills. Since 2007 he has been developing novel metrology at the University of Bath, working closely with leading aerospace companies. This research is currently focused on uncertainty modelling of production systems, bringing together elements of SPC, MSA and metrology with novel numerical methods.
Presentation: Why Gauge R&R is not Uncertainty and why Uncertainty is not what you think! There is a commonly held view on the shop-floor that a Gauge R&R study is the ‘true accuracy’ of a measurement process, since it is based on experimental observations, and that uncertainty is just theory. Within the Metrology community it is understood that there may be significant systematic effects contributing to the uncertainty which will not necessarily be observed in the standardised gauge R&R study. It is possible to experimentally validate an uncertainty providing a much more robust estimate than a standard Gauge R&R study. This is illustrated with some examples. What is less well known is that the GUM approach to uncertainty has a number of fundamental and practical issues meaning that it is not directly applicable to the evaluation of uncertainty within industrial processes. This is not addressed within standards recommending uncertainty for industrial measurements, such as ISO 14253 and VDA-5. An improved framework for industrial uncertainty is therefore required.
Zheng Wang, Research Officer, Mechanical Engineering, University of Bath
Dr. Zheng Wang is a post doc research officer at the Laboratory for Integrated Metrology Applications at the University of Bath, UK. Zheng’s research focuses on hardware and software integration of metrology systems for Metrology Assisted Assembly, modelling of instrument uncertainties and real-time metrology control of robots and machines, as well as robot dynamics and vibrations.
Presentation: Real-time laser tracker compensation of robotic machining. Due to their flexibility, low cost and large working volume, 6 axis articulated industrial robots are increasingly being used for drilling, trimming and machining operations. However, producing high quality components has proven to be difficult, as a result of the inherent problems of robots, including low structural stiffness, and low positional accuracy. These limit robotic machining to non-critical components and parts with low accuracy and surface finish requirements. As a part of the “Light Controlled Factory” project at the University of Bath, studies have been carried out to improve robotic machine capability, specifically positioning accuracy and vibration reduction. This presentation includes the description of the hardware, software and methodologies developed at Bath, to compensate robot path errors in real-time using a single 3DOF laser tracker, as well as the experimental results, including verification of dynamic performance with a Renishaw Ballbar, and a industrial machining case study with an aerospace company.
Jeremy Stern, Senior Manager for Quality Services, Jaguar Land Rover
Jeremy Stern is the Senior Manager for Quality Services within the Powertrain Product Engineering organisation at Jaguar Land Rover. He has responsibility for all Powertrain Product Engineering metrology, in-field data analytics and the complete Powertrain 6-Sigma Deployment. He has worked in the Jaguar Land Rover business for 19 years in a number of diverse roles ranging from leading the installation of major manufacturing facilities to product quality management and also as the 6-Sigma Master Black Belt delivering significant product and process improvement projects.
In support of Jaguar Land Rover’s latest Ingenium engine family launch, its passion for putting the “Customer First” and all of the other innovative and exciting products in the development pipeline Jeremy has most recently led the deployment of a new engineering metrology organisation. This has included the delivery of a brand new multi-million pound metrology facility utilising a range of cutting edge measurement technologies, the recruitment and development of a new team to run it as well as work to integrate metrology into the heart of the engineering process.
Presentation: Metrology – Anything But Manufacturing. In many manufacturing businesses and industries across the globe, traditional metrology is typically considered as a manufacturing domain activity. Whilst valuable, it is an opportunity lost if that is the only place it is applied. This presentation will explore how Powertrain Product Engineering at Jaguar Land Rover is working to apply metrology related activities to the whole product life cycle and some of the challenges faced in doing this.
Ben Adeline, Chief Executive, INSPHERE Ltd
Ben co-founded INSPHERE to address the emerging metrology needs of advanced manufacturing companies. INSPHERE offer unique integrated measurement solutions such as turnkey metrology automation cells. They also offer subcontract services, measurement training and consultancy and are actively engaged in research programmes developing future metrology solutions. These activities have led to INSPHERE being widely regarded as thought leaders in advanced metrology applications.
Before INSPHERE Ben was the Commercial Director of a metrology research laboratory. This metrology experienced is coupled with a deep knowledge of the Aerospace Industry, gained from his time working at Airbus where he led major manufacturing research programmes. This has allowed Ben to develop an insight into the challenges of manufacturing and the role that metrology could play in improving quality and productivity. Ben now leads a team of highly specialist metrology engineers at INSPHERE and is currently steering the company through a significant growth period driven by the increasing demand from industry for specialist metrology support.
Presentation: Metrology for Industry 4.0. The fourth industrial revolution is the much-hyped step change in manufacturing that is about to take hold, driving productivity up: creating new product and market possibilities. Envisaged benefits will be derived from connecting automation with computers using smart algorithms to analyse big data sets, thus creating cyber-physical systems. These systems will require little or no human intervention to self-correct and adapt to production demand and product changes. So how does metrology fit into this world and how will it shape the requirements of the metrology industry?
Measurement data has a potentially critical role to play in forming the foundation of data that communicates the status of machines or conformance of products. However, if metrology processes do not meet the future requirements it may fundamentally risk the ability to create true cyber-physical systems that can yield benefits for manufacturing. This presentation will explore this topic to suggest answers to some of these questions and pose many more thoughts and challenges to consider. Hopefully this will instigate a debate about the role metrology will play in the future of manufacturing.
Jerome-Alexandre Lavoie, Product Manager, Creaform
Jérôme-Alexandre Lavoie holds a physics engineering degree from Laval University in Quebec and he joined Creaform in 2007 as an application engineer. Over the years he became an expert in all Creaform technologies. After four years of working closely with customers, he became Product Manager with the mandate to develop Non-Destructive Testing solution u sing Creaform technologies. Jérôme-Alexandre accumulated 10 years of experience in 3D data management. He is now in charge of our complete portfolio or Quality Control technologies, including our automated inspection solution.
Presentation: Large Scale Metrology: Photogrametry a real alternative to Laser Trackers. Large scale metrology can be defined as measurement of parts from 3m up to larger than 100m with metrology grade tolerance. Such part size range can be found in various industries such as aerospace & automotive, but also in power generation and ship-building industry. The needs for large scale metrology in those industries can vary from controlling fixtures, part inspection and part assembly alignment also known as fixtureless assembly. Recent development of metrology grade optical technologies has created a real opportunity for productivity enhancement and economic saving for large scale metrology applications.
To this day, a major market share for large scale metrology belongs to Laser Tracker systems. This article focuses on solutions like photogrammetric systems as an alternative to laser trackers. This paper describes the various old and new challenges of large scale metrology. New trends expected to include: shop floor accuracy and simplicity. The goal is not to expose weakness of Laser Tracker, but to highlight how users can benefit from alternative technologies to enhance their measurement process and product quality.