Case Studies

Express Manufacturing Gains Full ROI with the FARO Gage

Express Manufacturing Gains Full ROI with the FARO Gage

Express Manufacturing Gains Full ROI with the FARO Gage

 

Express Manufacturing

did a trial program called the FARO Technology Test Drive (program valid for the American markets) which enabled them to evaluate the equipment in the “real world” situation of their own shop floor. With a minimal investment and no risk, they were able to test the Gage and prove out its ROI before purchase.

Express Manufacturing is a job shop that is dedicated to quickly producing accurate parts
for their customers. Based in Acton, Ontario,Express specializes in aluminum, mild steel, and even wood. With a goal of being an affordable machine shop, they focus on jobs with
smaller quantity outputs which best affords them the opportunity to do what they do best –
work quickly with accurate parts.

Problem
With a primary focus in the aerospace industry, specifically landing gear, Express Manufacturing
often must inspect bearing surfaces and mating surfaces with very tight tolerances. Solely using
micrometers and electronic height gauges on these parts created issues of time and material
waste and, generally, some frustration. Another issue that can also potentially hinder
achieving the desired high accuracy is the problem inherent with removing a part from a
tooling machine while in-process. Despite the best of efforts, it is difficult, if not impossible,
to set a part back into a machine for re-tooling exactly as it was before. In addition, simply
removing the part from a production machine for inspection and verification is, in itself, both
time consuming and expensive.

Solution
Inspecting parts directly on the machine >>producing them not only increases productivity, but also quality. On-machine inspection allows the machine tool operator to quickly and easily inspect parts directly on the floor while the part is being machined – resulting in tighter tolerances with fewer errors and re-work. Express Manufacturing was looking for a solution that would provide them the advantage of true onmachine inspection. That tool is the FARO GagePlus. The Gage is a highly accurate and easy-to-use measurement arm. It’s designed to be used directly on the shop floor and is ideal for on-machine inspection. Eric Wenger, the owner of Express Manufacturing, said, “On-machine inspection is where the FARO Gage shines and it really helps us a lot.”
They will still “double check” with the height gauge, but they can be confident in the part before
they take it off the machine. This saves them a lot of time, material, and that frustration.

Return on Investment
Express did a trial program called the FARO Technology Test Drive (program valid for the American markets) which enabled them to evaluate the equipment in the “real world” situation of their own shop floor. With a minimal investment and no risk, they were able to test the Gage and prove out its ROI before purchase. An added bonus for Express is now having a CMM
in their shop. They have since reverse engineered parts and have been able to verify the quality of parts they’ve been making for years. In fact, they verified their measurements using the FARO Gage with a very expensive table CMM and found no discrepancy at all.

“The implementation was very easy. Especially with the Test Drive program and training,”
said Wenger.
“We have better piece of mind now.”
The Gage has improved Express’ process measuring time and the accuracy of parts before taking them off the machine – again, saving a lot in material cost.
“The Gage turned a five week job into a three week one,”
said Wenger.
“We have saved about $15,000 so far in the year we’ve had the Gage and this figure would
be much higher if not for the rough economy. I project that FARO will save us about $25,000 to $30,000 a year in a normal economy.”

Wenger also said one unexpected benefit of having the FARO Gage is,
“It’s a great selling feature for when people come to see the shop. Customers like the fact
that it’s in the shop and we always make it visible when they come.”

About FARO
FARO develops and markets computer-aided coordinate measurement systems and measurement software worldwide. The portable measurement equipment from FARO permits high-precision 3D measurements and 3D comparisons of parts and complete systems within
production and quality assurance processes. They are used for inspecting components and component assemblies, production planning, and inventory documentation, as well as for the investigation and reconstruction of accident sites and crime scenes. They are also used for digital scanning of historical sites. Today, approximately 10 000 customers worldwide with more than 20 000 installations have put their trust in the company’s measurement systems (NASDAQ:FARO).

4 good reasons

Contact Measurement: Interchangeable ,probes mean the FARO Gage can be used to measure different geometries.

Ease of use: Universal hinges make it easy for the operator to move the Gage around all kinds of objects, minimising fatigue.

Volume of 1.2m: Small parts and moulds can be easily processed in the Gage’s 1.2m (4ft) measuring volume.

Portability: The Gage is a portable device for jobs needed on different areas of the shop floor.

 

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