The couplings in the RATO S product line from VULKAN consist of several cast parts. To achieve the required elasticity, two of these castings are joined in a technique known as vulcanization. The problem: technical drawings and actual cast parts did not
always correspond 100%. This meant that the employees needed additional time to rework them. To improve the production process, the first thing that was needed was an exact analysis of the cast parts. "We have over 40 versions and sizes in this product line," says Andreas Ladwig, Junior Lean Production Officer. "We would have needed years to capture their geometry using slide gages." A faster and more exact approach was required.
VULKAN introduced a T-SCAN CS laser scanner from ZEISS. This digitizes the topography of the workpiece with 210,000 single points a second. The data capture software from ZEISS generates a 3D model of the workpiece from these point clouds. The operator first mounts the cast parts on a vise in the production area. During the scanning process a ZEISS T-TRACK CS+ tracking camera mounted on a stand nearby records the points captured by the laser scanner in a virtually clamped coordinate system.
Ladwig and his colleagues compared the CAD models with the scans using the INSPECTplus software from ZEISS. They
then updated the 'old' CAD models and sent them to the cast parts supplier. They subjected the 'new' cast parts to initial sample testing via a laser scan. "It's all incredibly fast," says Ladwig. "If my colleague scans in the morning and I have time for the analysis in the afternoon, then we can complete the initial sample testing for the component in a single workday. We used to need weeks to do this." The optimization process has led to a major reduction in both the reject rate and in the time and effort required for reworking.