In an industrial context where dimensional accuracy is a determining factor for final product quality, the ability to measure, analyze and control variations in manufacturing processes becomes essential to ensure production stability. This case study presents an example of applying industrial metrology solutions to improve dimensional control in a manufacturer of machined components used in demanding industrial applications.
Customer context
The manufacturer produces high-precision metal components used in industrial equipment and mechanical systems where dimensional tolerances are particularly strict. Production is carried out using CNC machining processes and involves parts with complex geometries and multiple critical dimensional characteristics such as precision holes, functional surfaces and relative positions between geometric elements.
With increasing production volumes and growing customer requirements regarding dimensional quality, the company identified the need to strengthen its dimensional control processes. Although dimensional verification methods were already in place, these were mainly performed through manual measurements or conventional measurement equipment, which limited the ability to perform detailed analysis of dimensional variations.
Additionally, existing inspection processes did not provide a complete view of the dimensional behavior of parts throughout production. This made it difficult to identify deviations early and limited the ability of engineering teams to respond when variations occurred in the manufacturing process.
Technical challenge
The main challenge faced by the manufacturer was related to dimensional variability observed in certain critical features of the parts. Small variations in dimensions or the position of geometric elements could affect the functional performance of the components or create difficulties during assembly stages.
Another important factor was the time required to perform dimensional inspections. In some cases, measurement processes were too slow to keep up with production pace, making it difficult to use measurement data as a tool to support process improvement.
The company therefore required a solution capable of:
• improving the accuracy and consistency of dimensional measurements
• reducing the time required to perform inspections
• obtaining structured measurement data
• using this information to identify and reduce variability in the manufacturing process
Applied methodology
To address these challenges, a structured approach to improving dimensional control was defined with the support of NM3D IBERICA, a company specialized in industrial metrology solutions.
The first step involved analyzing the dimensional requirements of the parts and identifying the geometric features most critical to the functional performance of the components. Based on this analysis, a structured measurement routine was defined to provide consistent and repeatable data regarding the dimensions of the produced parts.
The adopted methodology combined different measurement technologies, allowing the advantages of each system to be leveraged in order to create a more complete and efficient inspection process.
The main dimensional measurements were performed using LK Metrology coordinate measuring machines (CMMs)capable of accurately measuring various geometric characteristics of the parts. The use of the CMM enabled partial automation of the measurement process and ensured greater repeatability in the results obtained.
To complement these measurements, additional verification points were defined using Nikon Metrology vision systems. These systems allowed rapid measurement of certain geometric features, particularly smaller elements or situations where inspection speed was necessary to keep up with production pace.
Technologies involved
The implemented solution combined three main technological components.
LK Metrology CMM
Used for high-precision dimensional measurements of critical part features, enabling accurate verification of dimensions, positions and geometric tolerances.
Nikon Metrology vision systems
Used for rapid measurement of specific geometric features, helping reduce total inspection time and improve dimensional control efficiency.
PolyWorks software
Responsible for measurement data analysis and structuring. PolyWorks enabled the organization of measurement results, generation of structured reports and creation of analytical tools to support the interpretation of dimensional data.
The integration of these technologies created a workflow in which measurement data became structured and readily available for analysis by engineering and quality teams.
Results and benefits
After implementing this measurement methodology, the manufacturer achieved significant improvements in the dimensional control of produced parts.
One of the main benefits observed was the reduction of dimensional variability in critical part features. The availability of more detailed measurement data allowed the company to identify trends and better understand the behavior of machining processes.
Another important benefit was faster response to production process variations. With faster measurements and structured reports, production teams were able to identify dimensional deviations earlier and adjust manufacturing parameters before problems spread throughout production.
Additionally, the partial automation of measurement processes improved inspection consistency and reduced reliance on manual measurements.
This case demonstrates how integrating different industrial metrology technologies — combining high-precision CMM systems, vision systems for fast measurements and advanced dimensional analysis software — can significantly improve dimensional control in demanding industrial environments.
By transforming measurement data into useful information for improving manufacturing processes, industrial metrology solutions allow companies to reduce variability, increase efficiency and ensure high levels of product quality.