Precision manufacturer's new 3D measurement system dramatically reduces inspection time
Located in Derby, Kansas, BG Automation specializes in large, machined components, such as structural plates. The precision manufacturing company was facing limitations in their existing inspection process. So, they turned to Keyence's latest 3D measurement system, and it completely changed the company's approach to inspection.
Serving industries where quality and traceability are critical, the team at BG Automation needed a solution that could handle complex parts efficiently, reduce inspection time, and make dimensional measurement more accessible across their team.
Challenge: Complex Inspections and Limited Usability
Prior to adopting a new 3D measurement system, the manufacturer relied on traditional tools including calipers, height gauges, micrometers, and a portable arm CMM. While the arm CMM offered 3D measurement capabilities, BG's inspectors felt it came with significant drawbacks:
- Steep learning curve: Only a few skilled inspectors could operate the system effectively.
- Frequent software updates: Keeping the system current required regular -- and often disruptive -- maintenance.
- Extended inspection times: Large parts like machined plates took 2.5 to 3 hours to inspect due to setup complexity and manual measurement.
VIDEO: Keyence XM-5000 -- BG Automation Testimonial
So, the team sought an alternative that would offer greater reliability, improved mobility, and ease of use for all inspectors, regardless of skill level.
Solution: KEYENCE XM Series 3D Measurement System
After their quality manager had previously seen a demo of an older XM model, the team decided to evaluate the latest KEYENCE XM Series as a replacement for their aging arm CMM. The decision was driven by the system's versatility, portability, and intuitive interface.
"The feature that stands out the most on the XM is the ability to have anybody become an inspector," said the lead user. "I put together a program, included pictures and videos with the augmented reality, and anyone can walk up and follow it step-by-step."
Key Benefits
- Drastically Reduced Inspection Time -- The XM has significantly accelerated the inspection process for large parts. A plate that once took up to 3 hours to inspect is now fully measured in under 15 minutes.
- Augmented Reality for Easy Training -- Operators follow a visual step-by-step guide with images and embedded videos, reducing onboarding time and eliminating the need for in-depth metrology expertise.[/il]
- True Portability -- The XM can be used directly on the shop floor or relocated between workstations and the quality lab without losing accuracy or requiring recalibration.
- No Wear and Tear -- Unlike arm CMMs, which have mechanical joints prone to degradation, the XM uses infrared light and camera systems with no moving parts, minimizing long-term maintenance needs.
- Clear Communication with Machinists -- The system's automated inspection reports include annotated images of each measured feature, making it easy to identify and correct dimensional issues.
- Efficient First Article Inspection and Buyoffs -- Inspection times for first articles and production buyoffs have been cut in half, leading to faster approval cycles and less production downtime.
Outcome: Empowered Team, Streamlined Workflow
The implementation of the KEYENCE XM Series has fundamentally changed the company's approach to inspection.
Now, any inspector -- regardless of experience -- can contribute to quality assurance with confidence. "Every one of my inspectors has gone through the e-learning videos, and they were up and running quickly," said the lead user.
With its ease of use, mobility, and dramatic time savings, the company inspectors believe the XM system has proven to be a worthwhile investment -- especially for high-mix, large-part manufacturing environments where flexibility and speed are essential.
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