Questionnaire
Answers from UsersComparison to Optical Comparators and Measuring Microscopes
IM-X Series[Image Dimension Measurement System]
What measurement problems did your company face when using optical comparators or measuring microscopes?
Hindrances with optical comparators and measuring microscopes
The time measurements take and the drive toward eliminating human errors are two challenges many of our customers face. Particularly with optical comparators and measuring microscopes, part positioning, focusing, and measurement alignment must all be done by hand. This means that measurement times and accuracy are highly dependent on personal technique.
Tool manufacturer
For fine corner-arc measurements, an optical comparator and a calculation processor can come in handy, but positioning and aligning the part, as well as specifying the three points on the corner-arc must be done manually. This means more work and results in subtle operator subjectivity in the measurement results, which is a problem.
Machined components manufacturer
First off, measurements take time. Every time you change the measurement item, you have to manually adjust the product on the measuring microscope so that it’s properly oriented. Sometimes you also have to replace the jig. Lastly, it takes an especially long time for measurements using virtual lines.
Stamping manufacturer
When measuring smaller objects, it’s impossible to get a measurement without increasing the magnification. For example, with measurements at tolerances of ±25 μm ±1.97 Mil or ±50 μm ±0.98 Mil, verification is not possible without zooming in to 50×. However, as the magnification increases, the projected image darkens, which is tiring on the eyes. This is time-consuming and increases the possibility of errors.
Resin molding products manufacturer
To achieve a good balance of space, the first floor of our building is for manufacturing, and the second floor is where the optical comparator is installed. This means we are constantly coming and going with parts, which restricts our flow. We cannot install the optical comparator in the manufacturing department, and we are not able to move the optical comparator easily.
How the IM-X Series differs from optical comparators and measuring microscopes: Just place and press to complete measurement in only 3 seconds
By specifying the measurement location in advance and loading that measurement setting, all you need to do for a measurement is place the target on the stage and press the button. Up to 5000 dimensional measurements can be performed in just a few seconds.
- ■ Place the measurement target on the stage.
- ■ Press the MEASURE button.
- ■ All points are measured in seconds.
What did you think when you first saw the IM-X Series demonstration?
Automotive parts manufacturer
I had noticed the “Just place and press” catchphrase, but I had my doubts before seeing the demo. Actually seeing it with my own eyes was astounding! We tried many complex measurements and we managed to achieve the significantly greater precision than with an optical comparator. I instantly fell in love with the Instant Measurement system and wanted to put it to use right away.
Metal cutting products manufacturer
Seeing the measurement in action had more of an impact than I thought it would. That’s because the IM-X is able to measure a part all at once, even with objects that have areas of varying thicknesses. In the demonstration, when our own part was measured, seeing the incredible depth-of-field and field-of-view the system had. That was quite the surprise.
Spring manufacturer
During the demonstration, we measured one of our products. All we did was place it on the stage and press a button, and an “OK” determination instantly appeared. Upon seeing that, I knew the IM-X was something we could use. Another point that caught my attention was the automatic calculation function of the virtual lines and virtual points. With an optical comparator, indexing needs to be done with manual calculations, which is always a struggle. With this feature, I got the impression that we could perform measurements that are more precise and require less time.
Stamped products manufacturer
During the demo, what caught my attention was the ease of use. I was surprised by how simple it was to register settings or measure a single item. Using a mouse, all you need to do is click where to measure. The ease of operation makes the IM-X well-suited for repeated measurements, which is perfect for companies that handle mass production, as our company does.
EFFECTS you can feel.
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01The IM-X Series helps improve both product quality and reliability.
Compared with optical comparators and measuring microscopes, the IM-X Series offers ease of use and identical results no matter who is performing the measurement. Implementing the IM-X Series not only makes it possible to eliminate inconsistent measurement values between inspectors, but it can also help to reduce inspection-related claims from suppliers.
In addition, measurement results can be saved automatically, and the ability to create reports means time and effort spent on data management can be greatly reduced, resulting in an enhanced quality control system.
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02The IM-X Series helps improve productivity while also reducing costs.
Using the IM-X Series for first article inspections or after tooling changes can result in shorter inspection times as well as improved productivity. The IM-X Series also allows for reduced time and effort for daily inspections, for reduced time required for training new inspectors, and for reduced overall costs.
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03The IM-X Series helps reduce delivery times.
For orders with a quick turnaround, it’s not possible to create products in advance. In such cases, it all comes down to whether reductions in the production, inspection, and shipping processes are possible. The shortened inspection times with the IM-X Series not only allows companies to handle work with quick turnarounds but it can also contribute to increased order quantities.
Comparing time and effort required for measurement, and the clear implications for annual production efforts
For example, let’s assume that conventional measurement methods require 10 minutes for one part. Conducting 50 measurements a day would amount to about 2000 hours per year. With the IM-X Series Image Dimension Measurement System, one measurement can be done in seconds, reducing the hours to just 40 per year.
For those companies that measure parts in high volume, the more time currently spent on measuring means a higher possibility for efficiently reducing time.
What effect did implementing the IM-X Series have?
Aircraft parts manufacturer
We have reduced inspection time significantly. With the ability to call registered setting patterns with just a few steps, quick switching of the product to be measured is possible. Also, the amount of inspections left to part-time workers has increased, which has helped improve the work efficiency of the entire company.
Cutting products manufacturer
The IM-X has come in handy when determining how many millimeters need to be shaved off in additional machining. It has had a significant impact on reducing human error in measurement and on improving machining accuracy. With the IM-X, we have been able to quickly respond to customer needs in addition to earning the trust of major automobile manufacturers as well as being chosen for all similar projects.
Component prototype manufacturer
Our company needs to manufacture a product uniformly and on a short turnaround. Our build-to-order manufacturing style makes it impossible to make products in anticipation of future orders. It’s only through the efforts of all of our workers are we able to meet our short delivery times every time. By adopting the IM-X, we were able to reduce the time required for measurements without hindering the quality of the measurements, which gave us an opportunity to enhance our system for meeting short delivery times.
What lead to your decision to implement the IM-X Series?
Pressed products manufacturer
Even though the system is not a device that directly improved our machining accuracy, we were able to discover problems that might occur in a product in advance. The IM-X became important in preventing defective products from being sent out. As a company looking to improve quality control, it is an absolutely necessary piece of equipment.
Electrical equipment parts manufacturer
Even though our recent orders seem like simple enough components, the required accuracy has been steadily growing, requiring more detailed measurements. As a result, individual point inspection times have increased required accuracy, we’ve had to increase the number of samples being measured. Our current inspection system lacks sufficient capacity to handle this, so we decided to utilize the IM-X.
Watch components manufacturer
Although I considered implementing the IM-X just from seeing the demonstration, I compared it with other products such as an optical CMM. I came to realize that optical CMMs require intricate programs to be made, which can be difficult. Also, measurements took about as much time and effort as with a measuring microscope. Even though our parts required initial setting configuration, it took less time than the optical CMM. In the end, the speed of initial configuration and the level of intuitiveness became the deciding factors.
Major automobile manufacturer
We implemented this system because the person performing inspections spoke highly of the system and its capabilities. In our company, we believe that in order to produce higher quality parts you have to start with higher quality tools. We think it’s very important, as a company, to create an environment where workers can do their jobs effectively and as efficiently as possible. I felt like the IM-X was a perfect match to our company idea.
What kind of company do you think the IM-X Series is most suited for?
Tool manufacturer
I think that, for any company that currently measures product dimensions by moving an optical comparator’s stage, or a company that measures rounded corners by using calculation equipment, the IM-X can significantly reduce inspection times.
Pressing products manufacturer
The IM-X is a machine that can aid in carrying out daily tasks. I think the biggest selling point for the IM-X is its strength in repeatability. I highly recommend this measurement instrument for any company that handles mass production.
Metal machined components manufacturer
The IM-X offers not only repeatable measurements but also simple measurements for single items. This means that it’s not just useful for mass-production companies but also for companies such as ours that process a wide variety of small lots. This measurement instrument is a no-brainer for any company that wants to produce things well.
Component prototype manufacturer
The phrase “a picture is worth a thousand words” particularly applies to the IM-X. Everyone should see a demonstration, and I think that people should try measuring one of their own target objects.
