Metrology data used to improve the manufacturing process to save cost

This case study discusses the metrology data process developed to eliminate parts wasted and time lost during a manufacturing and quality inspection process.

How to improve engineering metrology process

Case study

In 2015, we had the opportunity to solve the end quality of assembled luxury cars, and, in particular, develop a metrology tool that will change the way that cars are assembled using metrology data.

The company lost a very large amount of money during the assembly of their previous new model. It went into production a year before.

When the assembled cars came off the production line, most of them failed the quality inspection and audit. (I can vouch for this company by confirming to you that they have a very robust quality process.)

During our brief before accepting the job, the programme manager informed us of the problems they had, and the available metrology data to which we had access. His objective was for us to find a solution to their problem(s). To develop an metrology instrument, metrology tool or a metrology analysis approach that would eliminate all waste. A metrology instrument or method that would prevent assembled cars failing the quality audit.

We had access to all the metrology data of the components for the assembly line, and that of the vehicle bodies.

During the first build of a future vehicle model, we recorded all the defects. Analysed the processed metrology data. Made modifications. And prepared and developed our metrology analysis tool for the second build.

During the second build, we predicted where the defects would occur. We identified the defects and rectified them in the interim. Most of the non-compliances were rectified before the second build.

We predicted a quality non-compliance on only one vehicle out of the 18 vehicles of the second build. It was redicted before the component even left the supplier.

We managed to put in place metrology process methodologies to ensure no parts were rejected for assembly and quality on the assembly line. Thus, we had implemented a lean process and an improved quality process. Saving the company millions by avoiding waste.

Our work of streamlining the metrology process was very successful. We reduced waste in several areas like the assembly process, the way in which the metrology data was measured, recorded, and the processed.

In doing so, we reduced waste, unnecessary and inefficient tasks.

This is one of the ways that we can save you money. Whether it is for operations, or a continuous engineering process improvement.


This is an excellent example of us improving engineering processes. Cutting waste before shipping, making the your processes efficient, increasing your profit.