Case Studies

Machinist Achieves Greater Customer Satisfaction Levels with FARO

Machinist Achieves Greater Customer Satisfaction Levels with FARO

‘The customer is always right’. Some companies simply hold fast to the adage, while others take a successful approach of incorporating useful customer suggestions to best benefit their businesses. For example, an India-based tooling and machining specialist, Techno Engineers, accepted a few helpful customers’ suggestions that led the company to a positive transformation of its production process and business.

Established in 1985, Techno Engineers is a machine shop that specializes in manufacturing an array of high-quality special purpose machines (SPMs), robotic cells, jigs, fixtures, receiving gauges, welding fixtures, panel checkers, and tooling systems. The company is best known for its products of high functionality, dimensional accuracy, easy installation, low maintenance, rust resistance, and durability.

“We place great importance on quality control, and accurate measurements are required at every stage of the manufacturing process,” said Mr. Davinder Kumar Dhingra, Owner and Director of Techno Engineers. He shared candidly, “It was our customer who introduced us to the portable FaroArm that we now heavily rely on. Prior to that, we had little knowledge of this technology. Through our own research and the demonstration by FARO, we came to realize that it enabled us to be so much more effective.”
 

A Machine Shop’s Measurement Needs

Given the work that Techno Engineers engages in, the team performs measurement tasks frequently for the alignment, calibration, and installation of jigs, fixtures, and gauges that they make. In addition, they also conduct inspections and obtain dimensional calculations of components to ensure that their products meet quality standards before delivery.

Previously, the team relied on hand tools such as height masters, height gages, slip-gages, micrometers, and vernier calipers for measurements. While these conventional methods worked, it was very time-consuming. For instance, in the dimensional analysis of a pipe that the team machined, technicians could only access the outer corners of the structure with their tools. In order to inspect portions of the pipe that were further within the structure, Techno Engineers would have to cut the pipe in order to obtain measurements.

Mr. Dhingra added, “Back then, the inspection of one product alone would occupy a team of 4-5 people for several days. The accuracy of the results was heavily dependent on the skills of the operator, and there were certain complex structures that our existing gamut of tools were unable to handle. It was not ideal and we were determined to find a better solution.”
 

Taking the Customers’ Recommendation

The team at Techno Engineers has always worked closely with its customers, and the strong partnership created an atmosphere of open sharing and honest feedback. On separate occasions, the company’s customers — which include familiar names from the automotive industry, such as Hero, Maruti, and SKH Metals — recommended FARO’s measurement solutions to them. While Techno Engineers is familiar with solutions such as fixed coordinate measuring machines (CMMs), the idea of a portable CMM was new to them.

Each joint contains encoders that calculate the probe’s exact position in 3D space.

The measurement arm resembles a “human arm”. Each joint contains encoders that calculate the probe’s exact position in 3D space.

Fundamentally, portable CMMs provide the benefits of fixed CMMs with the added versatility of mobility, which allows operators to deploy the solution wherever there is a need. In addition to being less cost-prohibitive than fixed CMMs, portable CMMs do not require a controlled environment, making it more cost-effective to operate and maintain them.

When Techno Engineers first reached out to FARO in 2011, the team saw in a demonstration how the FaroArm could help enhance their entire production process, right from design through to manufacture, assembly, and final inspections. The company then decisively invested in a 9-ft FARO® Edge to meet their measurement needs, and the move has enabled Techno Engineers to boost customer satisfaction levels tremendously.
 

One Tool, Multiple Applications

Mr. Amit Singh, Technical Head at Techno Engineers, revealed, “Our work requires measurements to be performed at every stage of production, whether it’s first article inspection, in-process inspection, machine calibration, or alignment. Careful measurements at every step of the way helps us to make sure quality is not compromised at the fundamental level.” The team at Techno Engineers utilizes the FARO Edge in various stages of production at numerous different locations, including its measuring room, shop floor, on-machine, and even off-site at customers’ facilities. The single device is also deployed for applications that are vastly diverse.

The portable FARO Edge enables inspection anywhere on the shop floor.

The portable FARO Edge enables inspection anywhere on the shop floor.

Typically, the team works with parts that are as small as 10 × 10cm in size, or on SPMs as large as 2 × 1m. The corresponding weight range of these objects is relatively wide, from as light as 100g to about 1 metric ton (1,000kg). Despite the diversity in object size, weight, or shape complexity, the portability of FARO Edge allows inspection checks on these objects to be easily completed.

Operators no longer have to worry about moving a bulky, heavy object to a measuring room, or about finding a suitable hand tool that can accommodate the piece being checked.

Moreover, measurements taken with the Edge are much more precise and accurate than those obtained with conventional methods, enabling Techno Engineers to provide readings with tolerance of 20 microns.

Apart from improving the company’s levels of efficiency and accuracy, the FARO Edge also offers Techno Engineers the additional benefits of convenience and new competencies. The device’s powerful capabilities meant that it could effectively perform the functions of several traditional hand tools, simplifying the workflow tremendously. Mr. Singh recalled how the team used to face constraints when building gages, because their height master could only measure objects up to 600mm in size. He said, “Even with a large enough height master, we would still be limited by its capabilities — the tool would only indicate that there was a deviation, but we had no clue where and how to correct the error. With FARO Edge, Techno Engineers could evolve to manufacture a wider variety of products, keeping the business sustainable and also facilitating expansion plans.

In addition, the FARO Edge allows Techno Engineers to conduct CAD-based inspections in the final stages of production, just before products leave the plant. Mr. Singh stated, “We compare measurements of our components against original CAD data to check for any deviations. Any corrections that need to be made readily shows up on screen, and we can immediately zoom in to fix the problem areas. Until we are 100% satisfied with the quality, the part does not leave our plant.”

The FARO Edge’s infinite rotation can measure even hard-to-reach spots or angles.

The FARO Edge’s infinite rotation allows users to measure anything — even hard-to-reach spots or awkward angles.

The availability of digital data also means that reports can be easily generated through the FARO CAM2® Measure 10, the accompanying 3D measurement software. Since the customers are using the same software, Techno Engineers can easily use these objective reports as a source of reliable reference.

“At times, we perform joint inspections with the FARO Edge at our customers’ facilities,” said Mr. Singh. “We started doing this because there have been cases where our customers rejected our products, citing production quality issues, when problems were in fact due to distortions that happened during transportation. The ability to bring our measurement tool with us to check our products after delivery has eliminated these types of misunderstandings, and we verify any deviations with our customers.”
 

Enhanced Efficiency & Improved Capabilities

Using the FARO Edge, Techno Engineers can inspect complete bike frames within 60 to 90 minutes, with 1 – 2 team members instead of 5. Factoring in the time taken for corrections, assembly, and a second round of inspection, a process that used to take 7 – 10 days can now be condensed into just 1 day.

Mr. Dhingra concluded, “The improvement in efficiency is remarkable! FARO has really made the measurement and inspection process so much easier and quicker for us. Our team is adept with the FaroArm now, and we plan to invest in more of such solutions, possibly to help us in the area of profile projection.”
 

About Techno Engineers

Established in 1985, Techno Engineers is a machine shop that specializes in manufacturing an array of high-quality special purpose machines (SPMs), robotic cells, jigs, fixtures, receiving gauges, welding fixtures, panel checkers, and tooling systems. The company is best known for its products of high functionality, dimensional accuracy, easy installation, low maintenance, rust resistance, and durability.

Techno Engineers’ is based in Faridabad (Haryana, India) and its 1,500-sq yard production facility is divided into three segments — SPMs and various tooling; CNCs and VMCs; and Press Shop.

 

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