Hexagon's Manufacturing Intelligence Division has released the Autonomous Metrology Suite: Developed on the cloud-based Nexus platform, the software is set to transform quality control in the manufacturing industry. It minimizes programming times in the workflows of coordinate measuring machines (CMM) and helps manufacturers accelerate critical R&D and manufacturing processes while addressing the skilled labor shortage.
Manufacturers in the automotive, aerospace, and general mechanical engineering industries are all facing similar challenges: Shorter product life cycles and frequent design changes increase the demand for highly accurate measurements, while the number of qualified CMM programmers is declining. At the same time, quality data is not collected and is also insufficiently utilized. These challenges slow down the production of new parts and make it difficult for manufacturers to repeat measurement results of consistent quality at every layer.
Hexagon's Autonomous Metrology Suite is specifically designed for these challenges: A digital twin of each connected CMM synchronizes seamlessly with its physical counterpart, ensuring that the correct inspection program always reaches the right machine. This helps to avoid potential human errors.
All quality, usage, and environmental information is then fed directly into a cloud dashboard, creating a continuous 'digital thread' that enables data-driven decisions in manufacturing.
Reduced programming times
All applications of the suite feature a unified, intuitive web interface that guides both new and experienced users through the process. It facilitates the creation of CMM programs and reduces the knowledge required for proper operation. Depending on complexity, this shortens programming time from days to hours.
Subsequently, users can fully automate the deployment of the program on one or multiple CMMs, as well as execution and documentation, through a single interface. Hexagon's existing CMMs Global S, Tigo, and MAESTRO can be integrated into the same digital workflow; support for third-party hardware is planned.
Gary Peacock, General Manager of Metrology Software at Hexagon, says: 'The Autonomous Metrology Suite revolutionizes measurement programming with a code-free environment and an intuitive user experience that drastically reduces onboarding time for operators. This helps companies address the skilled labor shortage.'
Integrated applications of the suite support users
These efficiency gains are achieved through a series of closely integrated applications built on Hexagon's Nexus platform that automate and streamline the entire measurement process: Metrology Mentor ensures consistent inspection methods from facility to facility and eliminates the risk of two operators measuring the same workpiece in different ways.
To this end, the application automatically generates ISO and ASME-compliant inspection programs directly from CAD. By standardizing measurement techniques through the Metrology Mentor application, the platform ensures that measurement programs consistently meet standards for geometric and positional tolerances, regardless of the operator's qualifications.
Meanwhile, Metrology Reporting consolidates data from Hexagon's measurement and tomography systems as well as third-party systems, providing live analyses of batch quality, statistical insights, and complete part histories through an accessible and highly productive web-based interface.
Finally, the Metrology Asset Manager monitors calibration status, machine operation, errors, and environmental factors such as temperature, humidity, and vibration to ensure that machines are operational and measurements are reliable. Additionally, it provides usage data that helps users understand and improve overall equipment effectiveness (OEE).
Intuitive operation via drag & drop
Since all applications share the same intuitive user interface, users experienced with one app can easily operate the entire suite. They can move files simply by drag & drop. Instructions are displayed directly on the screen, and updates in one app are immediately reflected across the entire suite.
'The Autonomous Metrology Suite supports and relieves experienced metrologists by automating processes from programming to execution across multiple CMMs and reporting, eliminating bottlenecks in quality control through consistent measurements,' explains Peacock.
Initial experiences at Paragon Medical
As one of the first users, Paragon Medical has validated the potential of the suite: The company improved the transparency of its overall equipment effectiveness with the Metrology Asset Manager, democratized quality data with Metrology Reporting, and is now implementing standardized inspection processes while Metrology Mentor accelerates the onboarding of new employees.
Jeff Livingston, Senior Quality Manager at Paragon Medical, says: 'Like many other manufacturers, we are under increasing pressure to accelerate our production while dealing with scattered data and a lack of qualified CMM programmers. Manual monitoring of our 17 CMMs led to bottlenecks, inconsistent measurement strategies, and issues with operator training.
With the Autonomous Metrology Suite, which consolidates everything through a single intuitive interface, we now see a clear path to consistent quality and manufacturing. What used to take hours or days is now done in minutes – and this impacts throughput, training, and team communication.'
The Autonomous Metrology Suite includes on-premise software for synchronizing programs, digital twins of CMMs, and reports with Nexus. Additionally, this allows CMM programs to be executed without requiring measurement software like PC-DMIS. Future developments of the suite are expected to further simplify the rapid capture, analysis, and application of measurement data within manufacturing processes through the open connectivity, automation, and collaboration capabilities of the Nexus platform.
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