Measurement Case Study: Analysis of Experiment and Proposed Measuring System

This report presents series of data analysis of an experiment done in the laboratory. The assignment involves four measuring tasks. The first task will involve analysing the measured data in consideration with resolution and repeatability. This will lead to high accuracy in measurements.

Measurement Case Study
Student Name:
Student number:
Date:

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Contents
Executive summary.........................................................................................................................4
Introduction......................................................................................................................................4
Task 1...............................................................................................................................................4
Procedure of using the instrument...............................................................................................4
Digital clipper...........................................................................................................................4
Manual clipper..........................................................................................................................5
Results analysis............................................................................................................................6
Discussion....................................................................................................................................7
Task 2...............................................................................................................................................8
Proposed system requirements.....................................................................................................8
Proposed measurement system description..................................................................................9
reasons for the choice.................................................................................................................11
activity and costings and Gant chart..........................................................................................11
Task 3.............................................................................................................................................12
Measuring requirements.............................................................................................................12
Proposed measurement system..................................................................................................13
Training and maintenances........................................................................................................14
Calibration..................................................................................................................................14
Reasons for choosing the above system.....................................................................................14
Activity costings and Gantt chart...............................................................................................14
Task 4.............................................................................................................................................15
Measurement equipment requirements......................................................................................15
Proposed measuring system.......................................................................................................15
Gantt chart and activity costings................................................................................................19
Conclusion.....................................................................................................................................21
References.................................................................................................................................23
Figure 1 digital clipper used in measuring the part surface.............................................................4
Figure 2 showing a sample of holes to be measured image from (contributors, 2019)...................8

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Figure 3 digital Vernier caliper with range of 0mm to 150mm, no zero error and with inner
diameter claw, image credit (caliper ,2019)..................................................................................10
Figure 4 on/off for digital caliper image from Wonkeedonkeetools.co.uk. (2019).......................11
Figure 5 caliper storing box, image from Wonkeedonkeetools.co.uk. (2019)..............................11
Figure 6 full pack digital caliper costs 23.99 us dollars, image from Amazon website, 2019......12
Figure 7 table showing activities and their costings, with Gantt chart timeline for activities.......12
Figure 8 matrix array measuring system Qualitymag.com. (2019)...............................................13
Figure 9 showing matrix array scan for the system, image from Qualitymag.com. (2019)..........14
Figure 10 activity costing and Gant chart......................................................................................15
Figure 11 optical measuring system..............................................................................................16
Figure 12 Figure 3 larger system will be adopted to allow measurement of variety of components
(Nugent, 2019)...............................................................................................................................17
Figure 13 Gantt chart showing proposed timeline for activities....................................................21
Table 1 showing activity costing and the Gantt chart activities....................................................19

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Executive summary
This report presents series of data analysis of an experiment done in the laboratory. The
assignment involves four measuring tasks. The first task will involve analysing the measured
data in consideration with resolution and repeatability. This will lead to high accuracy in
measurements. The measurement task two, three and four involves introducing new
measurement system. The role of the task will involve analysing the probable equipment needed
for high precision measurement.
Introduction
Dimensional measurement refers to a field of science that specializes in metrology
(Muelaner, 2019). It gives understanding of units across continents, which is crucial for linking
human activities (Finkelstein, 2009). Modern dimensioning has its origins in in the political
motivation of the French Revolution to standardize units in France when a long standard was
suggested from a natural source (paktar, 2009). This led to the establishment in 1795 of the
decimal-based metric systems, which established a set of standards for other calibration types.
Between 1867 and 1976, several other nations adopted the imperial system; the Meter
Convention established the Bureau International les Poids et Measures to ensure uniformity
between the countries (Nugent, 2019).
Task 1
The task involves measuring a component lower section height using two metrology
instruments. The first instrument was manual clipper and the second instrument being a digital
clipper as shown in diagram below.
Figure 1 digital clipper used in measuring the part surface.
Procedure of using the instrument
Digital clipper
The first step is to open the calliper while approximating the part surface height. This
should be done carefully as the sliding jaw should be in contact with upper side of the object.

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In the second step, the jaws of lower calliper are extended until the jaws meet the lower side of
the part surface. To extend the jaws, a thumb screw is used.
The third step is to lock the jaws, in between is the part surface to be measured. Tighten
the jaws and remove the part surface if need be.
The fourth step will involve reading the measurements as displayed in the LCD screen.
The data from the digital clipper was as shown below.
sample
number
Height
(mm)
1 20.424
2 20.724
3 20.176
4 20.381
5 20.346
6 20.304
7 20.627
8 20.312
9 20.414
Manual clipper
The second instrument used was a manual clipper.
To take the measurements, same steps used in clipping the part were repeated.
The only difference was reading the measurements. The readings were done manually and the
zero-error compensated. The following were the results (Dowdy, 2009).
sample
numbe
r
Height
(mm)
1 20.23
2 20.23
3 20.38
4 20.23
5 20.24
6 20.17
7 20.31
8 20.25
9 20.42
10 20.2

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Results analysis
The results for task one was analysed as follows.
Manual calliper
sample numb
Reading(mm
) LS fit Remove fit
1 20.34
20.046
6 20.5924
2 20.23
20.392
2 20.1368
3 20.38
20.438
8 20.2402
4 20.23
20.485
4 20.0436
5 20.24 20.532 20.007
6 20.17
20.578
6 19.8904
7 20.31
20.625
2 19.9838
8 20.25
20.671
8 19.8772
9 20.42
20.718
4 20.0006
10 20.42 20.765 19.954
standard dev(mm): 0.087996212 0.21241
mean(mm) 20.299
2 sigma 0.175992424 0.42482
3 sigma 0.263988636 0.637229
Capability (tol/6
sigma) 0.378804184 1.222

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0 1 2 3 4 5 6 7 8 9 10
19.4
19.6
19.8
20
20.2
20.4
20.6
20.8
21
f(x) = − 0.00744999999999999 x + 20.4493611111111
The line of best fit equation is indicated in graph
Digital calliper
sample number
Reading(mm
) LS fit
Remove
fit
1 20.424
20.458
6
20.3775
1
2 20.724
20.505
2
20.6309
1
3 20.176
20.438
8
20.1493
1
4 20.381
20.598
4
20.1947
1
5 20.346 20.645
20.1131
1
6 20.304
20.691
6
20.0245
1
7 20.627
20.738
2
20.3009
1
8 20.312
20.784
8
19.9393
1
9 20.415
20.831
4
19.9957
1

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standard dev(mm): 0.168225626 0.2172
mean(mm) 20.41211111
2 sigma 0.336451251
0.43439
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3 sigma 0.504676877
0.65159
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Capability (tol/6
sigma) 0.198146586 1.222
0 1 2 3 4 5 6 7 8 9 10
19.4
19.6
19.8
20
20.2
20.4
20.6
20.8
21
f(x) = − 0.00744999999999999 x + 20.4493611111111
Discussion
The two callipers have different accuracies. The standard deviation for digital
calliper values was found to be 0.168225626 while that of manual calliper was
0.087996212.
The two instruments have uncertainties in their measurements. The readings in digital calliper
cannot be predicted since they keep changing. The manual calliper has high repeatability than the
digital calliper. Digital calliper is suitable for large scale measurements since its fast as compared
to manual calliper. Compared to Vernier callipers, the digital calliper is more reliable for batch
measurements, but with high tolerances. The manual calliper is accurate, but is subject to human
error, using it for measuring small batch components could be tiresome. Human errors would
inconvenience the final results.
Reasons for uncertainties and how to reduce them
Good measurements should be made without the influence of ambient factors. The
following are the main reasons why the instruments does not give consistent readings.

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 Room temperature changes
 Parallax
 Humidity
 Instrument errors
Possible solutions to the above problems
 Perform the measurements in well controlled zone
 Avoid human errors, such as parallax
Task 2
Task 2 is to identify a measuring instrument that will be used in measurement of turbine
bearing housing. The housings are brought in batches. Each batch contains 15-20 housing. The
total batches manufactured per month is two.
Proposed system requirements
 Can measure diameter range of between 22mm to 142mm
 Has tolerances range from +/-10 μm to +/-60 μm
 Reliable for large scale production measurement, i.e. 14holes in each housing, maximum
housings being 40.
 High returns
Figure 2 showing a sample of holes to be measured image from (contributors, 2019)
Proposed measurement system description
The proposed system must meet the required description above. In measuring the bearing holes,
a precise measurement tool is needed, for our case, a digital Vernier calliper will be used.
The calliper can measure in range of 1mm to 150mm as shown below.
The inner diameter claw will be used to measure the hole bearings.
Measuring method training
As discussed before, using digital calliper is much easier. The first step is to open the calliper
while approximating the part diameter to be measured. This should be done carefully as the
sliding jaw should be in contact with the hole part, the difference between task 1 calliper and this
case is the diameter type. The main goal is to achieve inner diameter of the hole.

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In the second step, the jaws of lower calliper are extended until the jaws meets the opposite inner
side of the part diameter. To extend the jaws, a thumb screw is used.
The third step is to lock the jaws, in between is the part surface to be measured. Tighten the jaws
and remove the housing if need be. The fourth step will involve reading the measurements as
displayed in the LCD screen.
Calibration
Since production is done in batches, it is expected that bearing housing of same batch same
tolerances. Calibration will be done twice in a moth, for batch 1 and batch two. This will allow
the company technicians to use sampling techniques for measurements. All bearings could also
be tested since there are only 40 bearings in total span of one month.

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Figure 3 digital Vernier calliper with range of 0mm to 150mm, no zero error and with inner
diameter claw, image credit (calliper ,2019)

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Maintenance
Always turn off digital calliper when not in use, use the on/off button to turn off and on
Figure 4 on/off for digital calliper image from
Wonkeedonkeetools.co.uk. (2019).
store the calliper in its box free from moisture
reasons for the choice
 The machine tolerance is within the specified range
 Cheap and hence has no effect to company’s investment
plan
 Easy to use
 No skills needed for operation
 Reliable
 No frequent maintenance or check
 No calibration needed

activity and costings and Gant chart
The measuring system does not require special housing, it could be kept in office wad drop or in
existing instruments store.
Figure 6 full pack digital calliper costs 23.99 us dollars, image from Amazon website, 2019
TASKS costs in STAR
T
EN
D
DAY
S
Figure 5 caliper storing box, image from
Wonkeedonkeetools.co.uk. (2019).

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preliminary research $
20.00 3/20 3/26 6
accessing company’s capability $
20.00 3/27 3/29 2
procurement $
20.00 4/1 4/7 6
buying Vernier callipers $
24.00 4/8 4/9 1
testing the callipers $
10.00 4/9 4/29 20
commissioning $
10.00 5/1 5/5 4
accessing costs and operational
activities
$
20.00 5/5 5/10 5
maintenance and care assessment $
20.00 4/8 6/1 54
other activities $
20.00 3/20 6/1 73
Figure 7 table showing activities and their costings, with Gantt chart timeline for activities
Task 3
Task requires a measurement system to be used in measuring the cylindrical turbine shafts. The
tasks are to be done on regular basis. The shafts are 720mm long.
Measuring requirements
 Can measure large numbers in minimal time
 Diameter tolerances of 14μm/100mm
 Length tolerances of +/-32 μm.
Proposed measurement system
A matrix array system will be used to measure different shaft measurements. This system has the
same functionality as the system used for task 4. A number of audits can be carried out,
including shaft diameter, taper angle, funk depth and shoulder run - out to the shaft's overall axis.
Line scan technology, as its title suggests, creates the appearance of the dimensions of the part
through a series of lines.

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Figure 8 matrix array measuring system Qualitymag.com. (2019).
The line sensors must be tipped relative to the part axis to measure edges and shoulders. Part and
feature diameters are shown as a series of interconnected points or dots, and measurement
calculations are made using this calculated part image. Small features are hard to measure
because of the low resolution.

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Figure 9 showing matrix array scan for the system, image from Qualitymag.com. (2019).
As shown above, using a series of lines, line scanning technology creates an image of partial
dimensions. The line detectors must be tipped relative to the shaft axis to measure edges and
shoulders.
Training and maintenances
The machine comes with a user guide for training purposes. The machine also has a repairs kit to
help the corporation technicians maintain the instruments on a regular basis. The machine will
not need any calculations as it has a data interpretation processor.
Calibration
Calibration will be done on the following circumstances
 Based on manufacturers recommendation
 In case of any mechanical or electrical malfunction
 Monthly calibration
Reasons for choosing the above system
Line scanning technology is quick and has been proven over 10 years in the field
The machine tolerance is within the specified range
Activity costings and Gantt chart
The activities for this machine will be same as that of installing task 4 system
TASKS STA
RT
EN
D
DA
YS
labour and money
costs
preliminary research 9/2 9/3 14 $
40.00
accessing company’s capability 9/3 9/7 14 $
20.00
sampling and identifying the
measurement parameters 9/7 9/1
2 45 $
120.00
procurement activities 9/9 9/1
1 14 $
10.00
securing the required space 9/11 9/1
5 14 $
200.00
acquiring the measuring machines 9/16 9/1
7 16 $
100.00
installing the machines 9/17 9/2
1 16 $
100.00
testing and certification 9/22 9/2 40 $

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4 100.00
commissioning 9/23 9/2
7 20 $
100.00
assessing the return or profits 9/25 9/2
9 14 $
1,000.00
accessing the operational costs for the
machine 9/24 10/
2 24 $
20.00
maintenances and future repairs 10/2 10/
5 24 $
20.00
any other activities 10/5 10/
7 14 $
100.00
Figure 10 activity costing and Gant chart
From the cost’s column, the machine has high return on investment. The maintenance costs are
low
Task 4
The tasks involve devising a way of measuring the industrial products for the provided
case study. The templet sheet provided displays a range of 6mm minimum and 120mm
maximum. This gives nominal values of the assembly products manufactured by the company.
Measurement equipment requirements
The company’s goal is to attain high accuracy, despite that, several considerations have been
listed below.
 Can measure 0.55 m x 0.35 m x 0.25 m pumps
 High accuracy
 Low costs
 Equipment training
 Return on investment
Proposed measuring system.
To achieve the above requirements, an intelligent system will be adopted. There will be
no calculations needed to choosing the proposed system. The proposed system will use optical
light to establish the exact measurements of the shafts and other components. The machine uses a
high-resolution CCD camera. The camera uses a line scan technology which creates images of
the dimensions needed. During the assembly process, components move along the line, as they
move, images taken by the CCD camera are reconstructed. The reconstructed images will be
used to provide measurements. This process does not involve human intervention; hence the
systems corrects itself in case of any irregularities. (Hazrat Ali, Kurokawa & Uesugi, 2014).

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The sensors used in this process are called line sensors. The camera communicates with
the line sensor to align the components according to the required dimensions.
Figure 11 optical measuring system
(Nugent, 2019)

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Figure 12 Figure 3 larger system will be adopted to allow measurement of variety of
components (Nugent, 2019)
The cameras and the sensors will be installed in the company production lines. A secluded area
for the machine installation must be established.
Training and maintenance
The machine comes with a user manual which will be used for training purposes. The
machine also has maintenance kit which will help the company engineers perform regular
maintenance for the instruments. The machine will not require any calculations since it has a
processor for interpreting the data.
Calibration
Calibration of the machine will involve programming the machine to meet the desired
inputs and outputs. The CCD cameras which uses scan technology will be used as measurement
inputs. The measurements are not limited to specific values, hence all ranges provided in

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specification manual can be measured by the proposed instrument. The machine measurements
are within the specified tolerances.
Reasons for the above choice
The use of optical measuring technology meets the measurement requirements established in the
previous section.
Because of the growing trend in smaller components, the optical measuring instruments becomes
more relevant. The company can adjust the measuring tool by reprogramming it, with no
physical change of the tool. This makes it reliable and flexible
Gantt chart and activity costings
Table 1 showing activity costing and the Gantt chart activities

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TASKS STA
RT
EN
D
DA
YS
labour and money
costs
preliminary research 9/2 9/3 14 $
40.00
accessing company’s capability 9/3 9/7 14 $
20.00
sampling and identifying the
measurement parameters 9/7 9/1
2 45 $ 120.00
procurement activities 9/9 9/1
1 14 $
100.00
securing the required space 9/11 9/1
5 14 $
200.00
acquiring the measuring machines 9/16 9/1
7 16 $
1000.00
installing the machines 9/17 9/2
1 16 $
100.00
testing and certification 9/22 9/2
4 40 $
100.00
commissioning 9/23 9/2
7 20 $
100.00
assessing the return or profits 9/25 9/2
9 14 $ 100.00
accessing the operational costs for the
machine 9/24 10/
2 24 $ 20.00
maintenances and future repairs 10/2 10/
5 24 $ 20.00
any other activities 10/5 10/
7 14 $
100.00

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prelimiery research
sampling and identifyng the measurement
parameters
securing the required space
installing the mechines
commisioning
ascessing the operational costs for the machibne
any other activities
9/2
9/12
9/22
10/2
10/12
10/22
11/1
11/11
Figure 13 Gantt chart showing proposed timeline for activities
From the cost’s column in table above, the machine has high return on investment. The
maintenance costs are low.
Conclusion
Standardization in measurement is very important. Companies use different metrological
tools based on their products. The following conclusion can be derived from the report (Tavella,
Milton & Inguscio, 2018).
 Companies focus on low cost and reliable metrology components (Djellal & Gallouj,
2013)
 The components should be effective even in the ever-changing trends in market.

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References
Amazon.com. (2019). [online] Available at: https://www.amazon.com/Proster-Stainless-
Electronic-Fractions-Measuring/dp/B074BRTM24?
ref_=Oct_BSellerC_256414011_0&pf_rd_p=3b5d423a-cf52-529e-ae10-
ec455d17e9fc&pf_rd_s=merchandised-search-
6&pf_rd_t=101&pf_rd_i=256414011&pf_rd_m=ATVPDKIKX0DER&pf_rd_r=V75AWNADQ
K8HKF8C1MDW&pf_rd_r=V75AWNADQK8HKF8C1MDW&pf_rd_p=3b5d423a-cf52-529e-
ae10-ec455d17e9fc [Accessed 17 Mar. 2019].
Contributors, T. (2019). Measurement of bearing clearance | Turbomachinery Magazine.
[online] Turbomachinerymag.com. Available at:
https://www.turbomachinerymag.com/measurement-of-bearing-clearance/ [Accessed 17 Mar.
2019].
Calliper, D. (2019). Diagram of Digital Vernier Calliper. [online] Online Wiring Diagram Data.
Available at: http://12.ni-system.de/diagram-of-digital-vernier-caliper.html [Accessed 17 Mar.
2019].
Djellal, F., & Gallouj, F. (2013). The productivity challenge in services: measurement and
strategic perspectives. The Service Industries Journal, 33(3-4), 282-299. doi:
10.1080/02642069.2013.747519
Dowdy, P. (2009). Measurement (pp. 67,54). New York: Crabtree Pub.
Finkelstein, L. (2009). Foundational Concepts of Measurement. Measurement, 42(9), 1269. doi:
10.1016/s0263-2241(09)00180-8
Hazrat Ali, M., Kurokawa, S., & Uesugi, K. (2014). Camera based precision measurement in
improving measurement accuracy. Measurement, 49, 138-147. doi:
10.1016/j.measurement.2013.11.057
Muelaner, J. (2019). An Introduction to Metrology and Quality in Manufacturing. Retrieved
from https://www.engineering.com/AdvancedManufacturing/ArticleID/14896/An-Introduction-
to-Metrology-and-Quality-in-Manufacturing.aspx
Nugent, P. (2019). The Basics of Shaft Measurement | Quality Digest. Retrieved from
https://www.qualitydigest.com/inside/metrology-article/072616-basics-shaft-measurement.html#
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Paktar, R. (2009). Measurement and instrumentation education. Measurement, 2(4), 212. doi:
10.1016/0263-2241(84)90056-3
Tavella, P., Milton, M., & Inguscio, M. (2018). Metrology (2nd ed., p. 45). Amsterdam: IOS
Press, Incorporated.

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Wonkeedonkeetools.co.uk. (2019). Digital calliper care and maintenance. [online] Available at:
https://www.wonkeedonkeetools.co.uk/calipers/how-do-you-look-after-a-digital-caliper/
[Accessed 17 Mar. 2019].