Mackay Consolidated

Key Automotive Parts Supplier Achieves Productivity Gains with ZScanner 3D Laser Scanner


 Mackay Consolidated Industries Pty Ltd is a 100% Australian owned private company which commenced operations in 1932 as a small but efficient supplier of automotive parts.  Over the years Mackay has successfully grown to become a major supplier of a diverse range of engineered rubber and bonded metal/rubber composite products for the automotive, defence, transport, construction and industrial markets and their products are now exported worldwide.
Mackay's commitment to uncompromising standards of excellence in product development, material formulations and all facets of production, has resulted in the successful penetration of new markets and sustained profitable growth. Success in these chosen markets has been built on a simple philosophy - understanding our customers' needs and providing timely, cost-effective engineered solutions.  This combined with technical expertise, customer-responsive service and commitment to continuous improvement, backed with sustained investment, ensures that Mackay's reputation for reliable, high quality, innovative products will continue.

Problem

Mackay in producing automotive hose components for the Australian automotive producers, and as part of their on-going quality improvement processes, are continuously looking for ways to further improve their quality of parts produced and to provide additional benefits and improved outcomes for customers.

The measurement and quality assurance of complex flexible components such as fluid hoses and the tooling used to manufacture these components has always been a source of conjecture and hence a key driver for a new quality improvement program at Mackay.  As well as improvements to part quality, Mackay were also looking for ways in which they could improve their production part approval process (PPAP) to provide both higher quality submissions for their clients as well as more detailed and easily understood documentation.

Solution

Mackay Consolidated approached Hi-Tech Metrology for a measurement solution for PPAP and production inspection for their flexible hose components and manufacturing tooling items such as hose mandrels etc.

 After considering a number of alternative solutions it was recommended that a 3D hand-held laser scanning device, a product called the ZScanner, from leading US-producer Z Corporation of Boston, in the USA be evaluated.

The ZScanner is able to capture 3D surface data of the rubber hose components by using a set of randomly-placed reference targets either on or underneath the object being scanned which are then located by the digital cameras in the ZScanner.  This enables the component being scanned to be rotated and turned over to capture the full 3D shape.

 As the 3D data is collected by the ZScanner scanner and it is processed in the ZScan software (supplied with the scanner) and automatically creates a triangulated mesh (or .STL) file.  Post-processing in PolyWorks/Inspector software then allows Mackay to produce full colour 3D report comparisons (so-called weather map reports) in which any part deviation (beyond the allowable level) from the customer's 3D CAD model is clearly indicated.

Using this type of workflow with the ZScanner 600 model and PolyWorks software Mackay could see the benefits flowing to both their internal quality improvement processes and in turn enhanced outcomes for their clients.   The ZScanner solution was easy and straight forward to use, empowering employees on the shopfloor to scan and measure products that I the past have proven to be difficult to measure due to their flexibility and complexity in shape and form.

Return on Investment

The biggest benefit to Mackay Consolidated from implementing this solution is the time savings. "With the ZScanner we can collect vast amounts of spatial data in less than half an hour," stated Arch Tatas, Quality Assurance Manager, at Mackay Consolidated. "With our previous measurement techniques this would have taken several days to complete."

Arch also likes the accuracy, repeatability, and flexibility of use with the ZScanner system. He especially likes that the fact that it can be used anywhere, inside the plant and the operators can hold the part in their hand whilst it's being scanned - support fixturing is only necessary where the product cannot retain its shape under its own weight, e.g. small diameter formed hoses. "What we can achieve with one person in hours using the ZScanner and PolyWorks software would otherwise take several people days to complete at a lower level of accuracy," commented Arch.

Our customers are now able to receive fully-detailed 3D dimensional reports on the quality of the products that we supply giving them full confidence in our manufacturing and process capabilities.