Shortening the Measurement Time, Reducing Workload and Improving Quality

Located off Biwa Lake at the foot of Mt Kagami, Komatsu Cabtec Co Ltd (Komatsu Cabtec) is part of the Komatsu Group that is best known as the world's second largest manufacturer of construction and mining equipment. Established in 1918, Komatsu Cabtec specialises in developing and manufacturing driver's cabins (cabs) for construction equipment.

Komatsu Cabtec currently owns 2 units of FaroArm? Platinum, 12ft and 8ft in length. They are used to measure the prototype of cabs, first-article model, as well as in the sample inspection of cabs and parts. The introduction of the FaroArm in Komatsu Cabtec's shop floor was as a result of a chance encounter at one of its mold maker vendor's premises.

Aging Layout Machine and Complex Shapes

Komatsu Cabtec was at the time on the market in search of a new measuring instrument to replace its aging Layout Machine. The machine had an extremely time consuming measurement process as it required anywhere from 30-60 minutes for the set-up. For parts with curved surfaces, it was necessary to rotate the object to make measurements in multiple angles. And with each shift, the machine had to undergo recalibration, which would take up to an hour. All in, the measurement process for a curved part took about 4 hours to complete.

Recent developments in the industry also made the layout machine increasingly ineffective. Greater emphasis on the design of construction equipment cabs saw a higher usage of curved surfaces so as to enhance appearance, and the Layout Machine was unable to accurately take these types of measurements. This meant that Komatsu Cabtec needed a measuring system that could cope with the change in requirements. "When I first saw the FaroArm at our vendor's shop floor, it was capable of measuring the angle of slope in 15 minutes. I was amazed by its ability to measure objects without the use of a surface plate," said Mr Kataoka, Supervisor in charge of Quality Assurance Division. "It can even measure complex objects easily."

The FaroArm made a great first impression, and Komatsu Cabtec then decided to purchase it after a discussion with several companies. This was based on the key merits that the FaroArm was user friendly, and capable of measuring objects with complex shapes.

Significant Time-Savings and Reduction in Workload

Komatsu Cabtec currently owns 2 units of FaroArm Platinum of different lengths. The 12ft measuring arm is used primarily to measure the cabs as it has a larger measurement range.

Utilised from 3 to 4 days a week, the 12ft FaroArm measures the prototypes, first-article models, and also performs sampling inspections. With the FaroArm, Komatsu Cabtec was able to easily and quickly compare its prototypes with the CAD data to detect deviations, which resulted in substantial time-savings.

The second arm, 8ft in length, measures a large number of small parts that are used in the cabs. Equipped with the Laser Line Probe (LLP), this arm has the additional ability of performing non-contact laser scanning. Approximately 30-100 parts are checked and measured monthly before they are fitted into the cabs. "The measurement time is reduced by half, leading to an increase in measuring speed," remarked Mr Kataoka.

"Furthermore, we purchased a 32" monitor last year and it enabled us to verify the scan data on a big screen. With the use of a large monitor, we were able to perform measuring accurately and speedily."

Mr Kataoka added, "Cab measurements used to take us 3 hours to complete but now, they can be done in just 1 hour. The reduction in hours resulted in cost-savings, and the FaroArm is serving us well in that respect. Also, parts measurement now takes just half the time to complete, and all this has contributed to a reduction in inspection workload."

Komatsu Cabtec has a basic environmental policy in place to conserve energy and eliminate waste and there has been a company-wide effort to implement various eco-friendly measures throughout its facilities. As a result of the adoption of the FaroArm, the improvement in energy savings made by the Quality Assurance Division has been commendable.

Vendors' Concerns

Mr Kataoka, Supervisor, shared an interesting story behind Komatsu Cabtec's implementation of the FaroArm. He said, "Our part suppliers were worried that the parts they supply may not be up to standard due to the extreme accuracy that FaroArm now provides us. I think this has pushed for an overall improvement in quality."

In another example, some of Komatsu Cabtec's vendors purchased the FaroArm simply because they believed FaroArm is the right choice, since Komatsu Cabtec is using it. The use of the same measuring instrument by various part suppliers has improved data reliability across the cabs manufacturing supply chain. As a result, the same method of measurement shared by the part suppliers has led to an overall quality improvement.

In addition, Mr. Fujii from the Inspection Department of Komatsu Cabtec's Quality Assurance Division is working on the acquisition of skills and training for technicians.

His department participates in the Kansai regional skill contest, organised by Komatsu on a yearly basis. In this measuring contest, 3D measuring systems are used and Mr. Fujii's department has topped the contest with full marks for two consecutive years. The department began with two technicians. Now, there are four and that number will eventually increase to six. As the FaroArm is easy and simple to use, anyone can pick it up quickly. However, the job still requires technical expertise and a 3-month training program is conducted for technicians so that they can measure objects more quickly and accurately.

All in all, Komatsu continues to be committed to maintaining world-class quality, and FARO has been an important factor.