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Inspection/Measurement 36 MoldMaking Technology April 2015 Control the Process to Drive Profitability By Dan Skulan This ultra-compact touch probe has strain-gage technology and is suited for small- to medium-sized machining centers. It provides 3D measurement and on-machine verifcation for machining contoured surfaces and complex shapes. Sealed to IPX8, this probe is designed to resist harsh machining conditions and is compatible with a variety of software packages. Process control technology boosts productivity and profitability through increased throughput of good parts, reduced inspection time and dependable production schedules. H aving squeezed every second out of cycle times with increased feeds and speeds, advanced tooling and coolants, and process standardization, shops are now looking to process control to boost productivity and profitability. They have zeroed in on waste reduction, reducing costs, and increasing throughput and velocity as solu- tions, all of which are powered by an expanded use of process control tools. Shops are increasing good part throughput, reducing inspection requirements and establishing dependable production schedules by using laser calibration, ballbar systems, five-axis inspection and gaging tools. Process Foundation A solid process foundation creates machining pro- cesses that are predictable, repeatable and capable of producing conforming parts—a key component of a successful lean operation. To achieve predictable productivity, a shop must eliminate variation at its source and establish a stable operating environment with preventive controls. Consistent conditions at the start of the process set the foundation for con- sistent results. Machine performance assessment and calibration ensure that performance is in line with process requirements and provide baseline data for comparison and diagnostics. Using laser calibration and a ballbar to prove the capability of the machining process eliminates guesswork and unnecessary part-handling, and increases machine uptime by reducing the need for troubleshooting. Ballbars measure extremely small variations in radius as a machine under test follows a programmed circular path around a mount on the machine table. Sensors in the ballbar capture Images courtesy of Renishaw Inc.