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Transform your manufacturing with flexible gauging

Common problems with custom gauges

Although custom gauges are quick to use and highly repeatable, there are several problems which can occur through their use.

In a design and manufacturing environment, improvements to parts can require upgrades to be made to previous designs. The costs involved with modifying a custom gauge can often be a limiting factor in implementing design improvements and producing better parts.

In many instances the modification of one part will have a knock-on effect to other parts being produced. As custom gauges are often part-specific, custom gauges have to be modified for any design change implemented. Factor the changes across multiple production lines and the costs really start to add up.

Common problems with hand gauges

Manual devices such as Vernier or digital calipers, micrometres and plug gauges are widely used across manufacturing operations due to their perceived ease of use. However, this perception often masks the high costs of the labour involved in using what often turns out to be a substantial quantity of devices.

Over time, workshops can build up hundreds of hand gauges, all of which require regular recalibration if they are to be trusted. Even once calibrated the repeatability can be highly variable from operator to operator, which can be clearly seen with Gauge R & R (Repeatability and Reproducibility) studies.

Another common perception is that hand gauges are fast, which is true if you are measuring just one or two dimensions, however many parts require multiple gauges which require considerable user intervention, and change over time. To speed up the gauging operation, these devices are often duplicated across a workshop resulting in considerable build-up of cost over time.

Why choose flexible gauging?

To control manufacturing processes on the shop floor, gauges have been used for decades, for example sets of calipers, go / no-go gauges or bore gauges. With advances in manufacturing, the need for new process control methods is increasing.

The Equator™ gauging system is a flexible gauge, designed to provide speed, repeatability and ease of use for manual or automated applications. It has proven to be an ideal solution as a single gauging system, which can cope with a range of parts and future design changes.

Using the MODUS™ software, included with Equator systems, it is simple to modify part programs to add or change features.

The high speed and repeatability of the Equator gauging system's automated routines have resulted in considerable cost savings. Which is one of the many reasons why hundreds of manufacturers worldwide are replacing their current gauging method with Equator versatile gauging.

Learn more

One Renishaw Equator gauge has eliminated at least four costly hard gauges in a new work cell. And that's just the beginning of the impact the company anticipates for its inventory of custom hard gauges, which can cost up to $20,000 each.

Meyer Tool (USA)