A leading automotive component manufacturer in the West Midlands was experiencing frequent breakdowns with their aging Zeiss CMM, causing costly production delays and quality control bottlenecks. The machine, critical to their ISO/TS 16949 certification, was failing calibration checks and showing increasing measurement inconsistencies.
The Challenge The client’s CMM was over 15 years old and had received only basic maintenance. Measurement errors were creeping in, affecting their ability to meet tight automotive tolerances of ±0.05mm. With production schedules demanding 24/7 operation, any unplanned downtime was costing thousands of pounds per hour. Previous service providers had been reactive rather than preventive, leading to emergency callouts and rushed repairs.
Our Solution CHE Metrology implemented a comprehensive preventive maintenance programme tailored to the client’s production schedule. We conducted a thorough assessment, identifying worn components and potential failure points before they became critical. Our scheduled service included complete mechanical inspection, precision squareness adjustments, and UKAS-traceable calibration. We also upgraded the controller software and replaced aging pneumatic components.
The calibration process involved systematic verification of measurement accuracy across the entire working volume using certified reference standards. Our technicians spent two days on-site, ensuring minimal disruption to production whilst delivering thorough maintenance. We provided detailed documentation showing measurement improvements and recommended a quarterly service schedule.
The Results Following our intervention, the CMM achieved measurement uncertainties of ±0.003mm, well within the client’s requirements. Unplanned downtime reduced by 95% over the following 12 months, and the client reported significant improvements in first-time measurement accuracy. The preventive approach meant potential issues were identified and resolved during planned maintenance windows rather than causing emergency shutdowns.
Most importantly, the client maintained their automotive certification without measurement-related non-conformances. The improved reliability allowed them to take on additional contracts worth over £200,000 annually. Our ongoing relationship now includes remote monitoring capabilities and priority emergency support, giving the client complete confidence in their measurement processes.
