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AUTOMOTIVE & NEV

Automated Metrology Solutions for Car Body Manufacturing

Quality assurance & real-time analyses across sites

The automotive supplier BENTELER manufactures parts and modules for chassis, car bodies, engine, and exhaust systems as well as e-mobility solutions, which are all subjected to strict safety inspections on a daily basis. “A B-pillar must last in the event of a crash. For this reason, we never compromise on quality,” Eduard Reuswich, Continuous Improvement Manager, explains.

For quality assurance, the company relies on optical 3D metrology by ZEISS. At their headquarters in Paderborn, Germany, parts are first digitized using a ZEISS ScanBox optical measuring machine and then analyzed with the inspection software ZEISS INSPECT. Plans for multi-site monitoring include implementing ZEISS ScanBox systems at additional locations, with inspection plans rolled out centrally across sites. The ZEISS PiWeb reporting software enables real-time analysis of global measurement data.

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Humans and machines improve efficiency and safety

To ensure a smooth production process, the automotive supplier relies on automated processes. Since introducing their first robot in 1975, their fleet of robots has now grown to 450, while 800 employees are in charge of operating the forming machines. The smart cross-linkage of humans and machines is decisive for long-term success. Another key to success is product quality. To ensure quality at an early stage, the headquarters operate three ZEISS ScanBox systems.

Inspecting parts with the optical measuring machine makes it possible to quickly identify deviations and initiate the relevant corrective actions. The precise sensors measure complete surfaces, including hole patterns and trimmings, within a few minutes. The results are evaluated with the ZEISS INSPECT software, comparing full-field deviations between actual data and the CAD model.

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Producing competitive, safe, efficient, and eco-friendly vehicles requires innovative solutions. Explore how automated measurement technology enhances efficiency of quality control in the production and manufacturing process of car bodies.

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Effective quality assurance worldwide

Multi-site quality assurance is a defining characteristic of BENTELER: Creating prototypes, fixtures, and programs in Paderborn and then training employees locally in optical measuring systems with the respective parts significantly improves the implementation at other sites. The plug-and-play systems can be used at other sites without any major setup efforts – for example, at the production site in Kariega, South Africa. The plant recently received a ZEISS ScanBox to inspect structural components. “We programmed everything here and then shipped the system including the components over there. All project managers and quality assurance employees love it,” Sebastian Kuhlenkamp, Global Metrology Expert, explains. Standardized reporting with ZEISS PiWeb is another advantage. Thanks to the software, measuring results from other plants can be directly linked to decisions at the Paderborn site. This way, Michael Lindenblatt’s team is able to efficiently track production quality worldwide. Employees at other production sites also benefit from the software: “The provision of live data helps them monitor the quality of their products, take immediate action, and be fully informed at all times.”

ZEISS ScanBox is the established standard

In recent years, BENTELER has continually developed its focus on optical 3D metrology. While ZEISS ScanBox has been used mainly for measuring simple sheet metal parts in the past, the automotive supplier now also measures complex parts with the optical measuring machine. Lindenblatt is very satisfied with this development: “We measure a lot more often now and also obtain more information through the scans. Editing and continuously visualizing this data in ZEISS PiWeb will greatly support both the technology and us.” 

Sebastian Kuhlenkamp, Global Metrology Expert at BENTELER

“We programmed everything here and then shipped the system including the components over there. All of the project managers and quality assurance employees love it.”

Sebastian Kuhlenkamp
Global Metrology Expert at BENTELER

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Master your quality data worldwide

Companies face challenges with fragmented storage systems and inconsistent data formats, leading to traceability issues and regulatory compliance challenges. Find out how companies like Volkswagen use ZEISS PiWeb to streamline quality data collection and evaluation, enhancing efficiency across global operations.

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