“By analysing measurement data alongside other operational data, manufacturers can identify trends, optimise processes, and improve overall efficiency. Leveraging data-driven insights can enhance production efficiency, minimise downtime, and reduce scrap rates. The synergy between advanced metrology and intelligent monitoring extends beyond quality control to encompass holistic process optimisation,” says Paul Weaver, Director of Sales & Marketing, Renishaw India, in conversation with Neha Basudkar Ghate.
Can you explain the role of metrology in enhancing precision and quality in die and mould manufacturing? How critical is it to meet the increasingly stringent demands of emerging industries like semiconductor and electronics, aerospace and defence, automotive, and heavy machinery, among others?
From the core of businesses to the heart of manufacturing, metrology has always been vital in precision manufacturing to ensure that the products meet quality and design specifications. The die and mould industry is one of the focus business sectors given its significance in established economies and in rapidly growing economies of the world.
Advanced metrology solutions enable precise measurement and control of manufacturing processes. This ensures that moulds and dies are produced with high accuracy, reducing errors and improving the final products’ overall quality. The aerospace, automotive, food and beverage, and medical sectors rely heavily on components produced in mould tools and metal parts shaped by dies. Meeting the stringent demands of these industries requires continuous advancements in metrology to ensure high precision, reduced waste, and improved overall efficiency.
The machine tool market is growing rapidly, driven by advanced automotive, aerospace, healthcare, semiconductors, defence, Industry 4.0 expansion, and an increasing demand for precision. India is emerging as a key player in global manufacturing, attracting significant investments due to its role in the ‘China-Plus-One’ strategy, making it a preferred destination for the automotive and aerospace industries.
Can you please elaborate, preferably with a case study, on how precision manufacturing solutions are helping manufacturers across the globe deal with production challenges?
Precision manufacturing solutions are helping manufacturers around the world tackle new production challenges. These include the increased demand for innovative new products with more complex parts, higher design specifications and shorter product lifecycles.
Let me explain this with an example. A client in high-volume manufacturing struggled with maintaining product quality due to fluctuations in temperature and humidity, which led to increased scrap rates and impacted production yield. By implementing Renishaw’s process control solutions, the client monitored key parameters and used its measurement tools to ensure that the machine tools were properly calibrated. The system automatically adjusted to compensate for environmental changes like temperature variations, maintaining tight tolerances, and consistent product quality. This resulted in improved cycle times, reduced scrap, and increased production volume without investing in new machinery. The client also provided better quality reports, demonstrating consistent adherence to standards. Overall, this improved operational efficiency, extended machine tool life, and reduced the need for frequent replacements.
How do you assess the current state of the metrology market, particularly in the die and mould industry? Can you provide insights into the market size and growth potential in India and globally?Rising demand for metrology solutions in the automotive industry and general manufacturing is expected to drive the market. The die and mould industry, which relies heavily on precision measurement, is a significant part of this market. As automated facilities quickly take over the manufacturing of automobiles, the automotive industry is predicted to undergo a significant change soon. An increase in the need for electric vehicles and the requirement for highly dependable and high-quality procedures are anticipated to drive the market. Additionally, a rise in automation is likely in the manufacturing sector’s demand for industrial metrology during the projection period.
The growth is fueled by initiatives like ‘Make in India’, which emphasise quality assurance and standards compliance in manufacturing. Additionally, the increasing adoption of smart manufacturing and Industry 4.0 technologies is boosting the demand for advanced metrology solutions.
As India shifts from low-cost to high-precision manufacturing, domestic producers are offering advanced, cost-effective tools, which is prompting global players to lower prices and invest in enhancing localised support. Both global and domestic manufacturers are heavily investing in production, support teams, and new product launches. With India’s growing position as a manufacturing hub, the machine tools market is set for continued growth, technological advancements, and increased competition.
Globally, the increasing R&D investments in 3D metrology, rising integration of IoT sensors into industrial metrology solutions, growing focus on quality control and inspection in precision manufacturing, and the mounting deployment of autonomous driving technologies are the major factors driving the market growth.
What are the current challenges facing the metrology industry, especially in terms of standardisation and ensuring interoperability between the different measurement systems and manufacturing software platforms?
One of the most prominent challenges in metrology is keeping up with the rapid pace of technological advancements. In the digital age, measurements have become increasingly precise and reliant on cutting-edge technology. The challenge lies in developing measurement techniques that can accommodate new technologies and accurately measure parameters that were once considered impossible to quantify. International standards and harmonisation, measurement uncertainty and big data analysis are also the major causes.
It is important to offer flexible measurement solutions for both on-machine and off-machine applications. The adaptability of these systems is driven by programmable software, which makes it suitable for various production environments, from small batch to high-volume manufacturers. Application and service support teams work closely with clients to automate solutions and provide training, ensuring effective system usage. Also, the integration with automation and data collection provides real-time insights into production lines, enabling continuous improvement by automating production, reducing waste, and ensuring first-time-right quality.
The importance of data analytics in manufacturing is growing rapidly. How can advanced metrology systems harness the power of data analytics to help manufacturers optimise their operations, reduce waste, and improve product consistency?
Integration of metrology with advanced data analytics will provide deeper insights into production processes. By analysing measurement data alongside other operational data, manufacturers can identify trends, optimise processes, and improve overall efficiency. Leveraging data-driven insights can enhance production efficiency, minimise downtime, and reduce scrap rates. The synergy between advanced metrology and intelligent monitoring extends beyond quality control to encompass holistic process optimisation.
A structured approach to manufacturing can enhance precision and efficiency at every stage. By integrating different production phases through a centralised system that unifies measurement data, manufacturers can make more informed decisions, improve process reliability, and reduce waste.
Along with a structured process, the smart manufacturing data platform, which connects shopfloor machines, gathers machine-related data, workpiece data, and machining process data from every machine in the factory, providing a unified view of the shopfloor. This platform enhances connectivity, consistency, and confidence by collecting data from every stage of the process, helping to establish a robust system framework across the plant. The platform enables one to monitor and update machining and quality control systems.
Innovation in measurement technologies is continuously advancing. What do you believe are the most promising technologies in the metrology field that will shape the future of manufacturing and enable better product design, quality assurance, and cost reduction?
The focus should be on advancements aligned with smart manufacturing and IoT trends. Although the Indian market is still largely manual, it is viable to invest in faster manufacturing and measurement solutions.
As industry demands have increased over the years, we have seen a transformation in measurement technology. This includes smart manufacturing, IoT trends, innovations driving change in precision measurement, real-time data collection and data integration.
In recent decades, the manufacturing industry has seen the development of solutions aimed at simplifying automation and improving process control. One such advancement is the use of compact wireless machine tool probes that enable precise measurements directly on machine tools. Data-driven manufacturing software platforms have also emerged, enabling integration between measurement machines and CNC machines to improve the automation of process control. Multi-sensor systems, which are part of CMM measurement systems, allow seamless switching between different measurement modes, such as tactile scanning, vision, ultrasonic, and surface finish inspection, within a single setup. On the shopfloor, gauging systems paired with intelligent process control software can continuously monitor machining operations and automatically adjust parameters to maintain dimensional accuracy and stay within control limits.
The benefits of these technologies include improved product design by enhancing measurement accuracy, allowing for better design validation and iteration, leading to superior product quality. Quality assurance on real-time monitoring and feedback ensures consistent quality throughout the manufacturing process. Cost reduction on automation and integration reduces manual interventions, setup times, and waste, leading to significant cost savings.
This interview was published in TAGMA Times
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