hydra2: an automated product qc system that … · hydra: high yield ... manned visual inspection...
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8 2 0 1 E a s t R i v e r s i d e D r . , S t e 1 5 0 , A u s t i n , T e x a s 7 8 7 4 4
HYDRA2:AnAutomatedProductQCSystemthatEliminatesNdFeBCoatingDefectRisk
08Fall
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UrbanMiningCompanyProductorservicenamesareregisteredtrademarksortrademarksofUrbanMiningCompanyintheUSAandotherCountries.®IndicatesUSAregistration.Otherbrandandproductnamesaretrademarksoftheirrespectivecompanies.Copyright©2018UrbanMiningCompany,Tx,USA.Allrightsreserved.Allinformationincludedinthisdocument,andallAnnexesorAttachmentsheretoisSTRICTLYCONFIDENTIAL.Nodisclosureofthisinformation,whetherpurposefulorinadvertentisallowed,unlessfirstapprovedinwritingbyanauthorizedagentofUrbanMiningCompany. 2
Urban Mining Company, USA MagnetQualityInspectionProcessesSummary
Magnetmanufacturers establish process controls to ensure efficiency in production and
limit Critical to Quality (CTQ) failures in field strength, reversible loss coefficients, size
tolerances,andcorrosionresistance. Inorder tocommunicatecontrols,magnetsuppliers
report theirprocesscontrols tocustomersusingstandardmetrics (e,g,Cpk,Ppk,process
FMEAanalysis,GR&R,etc.)thatexhibittheefficiencyoftheirinternalprocesses.Nomatter
what the report shows, themagnet company’s processmust accept a certain amount of
failuresperproductionbatchwiththeaimtocontinuallyreducethenumberoffailuresper
productionbatch.
Tomitigatetheriskoffailuresinthefinalapplicationsandstrengthenthepresentationtoa
potential client, magnet manufacturers implement product controls like sampling
proceduresforfurthertesting.Forexample, ISO2859-1isatoolthathelpssuppliersand
customers define sampling plans for different inspection levels (reduced, normal,
tightened)inordertoagreeonstandardizedsamplingprocedure.Companiesusesampling
proceduresbecause100%productinspectionhasalwaysbeenconsideredimpracticaland
uneconomical.
However with all of these control measures, some customers report poor corrosion
resistanceas leadingcauseofmagnet failure, inotherwords,poorcoatingquality.These
coatingfailuresarearesultofoutdatedprocesscontrolsandpoorriskmitigationplansthat
followinferiorinspectionstandards.
As a newmarket entrant and innovativemagnetmanufacturer, UrbanMining Company,
aims to exceed customer expectations by raising current industry quality control and
processcontrolstandardsbyestablishinganewnormal.
a
UrbanMiningCompanyProductorservicenamesareregisteredtrademarksortrademarksofUrbanMiningCompanyintheUSAandotherCountries.®IndicatesUSAregistration.Otherbrandandproductnamesaretrademarksoftheirrespectivecompanies.Copyright©2018UrbanMiningCompany,Tx,USA.Allrightsreserved.Allinformationincludedinthisdocument,andallAnnexesorAttachmentsheretoisSTRICTLYCONFIDENTIAL.Nodisclosureofthisinformation,whetherpurposefulorinadvertentisallowed,unlessfirstapprovedinwritingbyanauthorizedagentofUrbanMiningCompany. 3
In order to solve this quality problem UMC is investing in state of the art process and
product control technology to reduce the impact of the known sources of process
variability - human interaction, machine variability, measurement process variability,
environmentduevariability,sourcingmaterialvariabilityandmethodduevariability.
HYDRA:HighYieldDefinitionResolutionAcquisitionSystem
UMCisbuildinganautomatedvisionsystem,HYDRA2,whichwillconduct100%product
inspection at a high throughput, relieving the customer from uncertain quality levels.
HYDRA2cancheckcontinuousvariableslikedimensionsandcoatingthickness,with2um
and 10 um accuracy, respectively, while keeping repeatability under 2 um. Attribute
variables,likesurfacedefects,aremeasuredwith2umaccuracyand100%repeatability.
Currently other automated inspection systems can only measure dimensions with an
accuracyrangebetween20umand100umandrepeatabilityrangefrom50umto20um.
The current technology is limited by computational speed, which forces the application
designertoworkwithlowerresolutiondetectorsinordertoachieveahighthroughput.
Because most vision systems provide unreliable results magnet producers implement
additional processes to double check measurements with the aid of manned visual
inspection and ISO2959-1.This systemcreates an economicaldisadvantagebecause the
mannedvisualinspectionneedsaconsiderableworkforceinordertocheckthedailyparts
amount required to meet production schedules. Additionally, the operators use
measurement methods that cause a performance disadvantage because standard
micrometers are often not regularly inspected and calibrated. Themeasurement itself is
subject to bias due to the operator’s eyes fatigue or tendency to rush when pay is
dependentontheamountofprocessedparts.
HYDRA2ontheotherhandisfullyautomatedwithapushofabuttonandcalibratesinless
thanoneminute,thereforeensuringaccuratepartanalysisbeforeeachdeliveredbatch.
a
UrbanMiningCompanyProductorservicenamesareregisteredtrademarksortrademarksofUrbanMiningCompanyintheUSAandotherCountries.®IndicatesUSAregistration.Otherbrandandproductnamesaretrademarksoftheirrespectivecompanies.Copyright©2018UrbanMiningCompany,Tx,USA.Allrightsreserved.Allinformationincludedinthisdocument,andallAnnexesorAttachmentsheretoisSTRICTLYCONFIDENTIAL.Nodisclosureofthisinformation,whetherpurposefulorinadvertentisallowed,unlessfirstapprovedinwritingbyanauthorizedagentofUrbanMiningCompany. 4
CoatingProcessControl
Theabilityofacoatedmagnet toresist tocorrosiondependsonthesurfacequalityafter
machiningprocessesandby thecoatingprocess.Pinholesandbubbles in thecoating, for
instance, are cause of coating failure resulting of poor surface finishing andpreparation.
Bubbles can be formed when the magnet surface is not properly cleaned, for example
residual grease is left on themagnet surface causingpoor adhesion of the coating layer.
Pinholes can be caused by surface roughness higher than1 umwhich allows the acidic
solution,usedintheactivationprocess,tostayonthemagnetevenafterrinsingandprior
to the deposition of the coating layer. The acid droplets will ultimately go through the
coatingofferingaspotforcorrosiontoattack.
ThekeytoUMC’sapproachintheprocesscontrolmeasurementsystemistoeliminatethe
human factor, through the implementation automated measuring system whenever
possible.Forexample,UMCisabletoproducesurfacefinishingwithroughnesslowerthan
0.8 um RMS thanks to state of the art surface grindermachines. Laser profilers control
surfaceroughnessonasampleplansetup toensureadeviation fromtheactualvalue is
lessthan0.1um.
Conclusion
HYDRA2willidentifyfailuresbeforeanymagnetsareshippedtothecustomer,therefore
providingthecustomerwithaZEROdefectedmagnetsrelatedtocoatingandsizeCTQ
parametersdefinedbythecustomer.
Processcontrolisalwaysnecessaryforincreasingefficiencyofaprocess.HYDRA2will
preventdeliveryofdefectivepartstoacustomer.However,ourultimategoalistocontrol
theprocesssowellthatHYDRA2willnotidentifymanydefectssowewillachievealow
attritionrate.