• Introduction to metrology, the roles of the metrologist and inspector
• Importance of the inspection function
• Measurement uncertainty overview
• Basic operating principles, strengths, weaknesses of the three major categories of Inspection tools (attribute or functional  gages / variable measurement devices / algorithm based measurement devices)
• Functional gaging types, design principles, and tolerances
• Considerations affecting part verification
• Inspection planning and reporting
• Inspecting size dimensions
• Simulating datums
• Inspecting GD&T requirements using  tools from the three major categories of inspection tools

The scope of the workshop does not include measurement systems analysis or sampling strategies. For example, the workshop will discuss how to locate a part for inspection on a CMM, but it will not cover how many parts should be inspected to meet AQL levels.

Who Should Attend
This workshop is a valuable tool for individuals who inspect parts, create inspection plans, or approve inspection methods. Typical attendees include CMM operators, inspectors, gage designers, manufacturing engineers, technicians, supplier quality engineers.

Workshop Highlights
The workshop focuses on inspection techniques for first article or fitness for use verification, including:

• How to make a working sketch of  a functional gage
• Identifying the appropriate tools for verifying each geometric control
• Improving quality and efficiency through a proper verification of engineering requirements
• CMM meaurement strategies

Each workshop participant receives:

• Inspection and gaging workshop exercise workbook
• Class handouts
• An official certificate of completion

Skill Level Needed
Workshop participants should:

• Be familiar with reading engineering drawings
• Have a good understanding of GD&T based on ASME Y14.5
• Be familiar with common inspection methods and tools from the four categories of inspection equipment  (i.e. functional  gages, open set-up inspection, CMM basics, calipers, micrometers, height gages, shadowgraph, etc.)

Format: This workshop is based on a set of goals and objectives that highlight important topics from each lesson and provide a method to measure what skills are learned and what skills need further study.

Course Agenda and Highlights
This is an interactive workshop. You will work numerous practice problems relating to both interpretation and inspection of GD&T requirements. You will be involved in discussions about the interpretation of GD&T and methods for inspecting GD&T requirements. Topics covered include:

Understand the functions of inspection in an organization.

• Describe what quality is
• Explain the purpose of a quality manual
• Explain five items that should be in a quality manual
• Describe what metrology is
• Describe what a metrologist is
• Describe four roles of a metrologist
• Define what inspection is
• Describe what an inspector is
• Describe why inspection is important
• List five roles of an inspector
• Describe four types of inspection

Understand what measurement uncertainty is.

• Define six terms related to measurement uncertainty
• Explain why measurement uncertainty is important
• Describe what measurement uncertainty is
• Explain the difference between type A and type B uncertainty
• List the eight common contributors to measurement uncertainty
• Recognize six items in each common contributor to measurement uncertainty
• Explain what a decision rule is
• Describe three factors that affect the choice of a decision rule
• Describe the terms, “guard band,” “simple acceptance,” and “simple rejection”
• Explain the four decision rules for measurement uncertainty
• Describe the four requirements of a decision rule
• Describe how measurement uncertainty affects product costs

Understand how to make a measurement/inspection plan.

• Describe what a dimensional measurement plan (DMP) is
• List three purposes of a DMP
• Describe three reasons why a DMP is important
• Describe five inputs to a DMP
• Explain what a critical characteristic is
• Explain the seven steps to creating a DMP

Understand the basic operating principles, strengths, and weaknesses of the three major categories of inspection tools.

• List the three categories of inspection tools
• List three tools from each major category of inspection tools
• Explain the basic operating principles of an attribute gage
• Explain the basic operating principles of variable measurement
• Explain the basic operating principles of algorithmic measurement
  

Understand attribute gaging design and use principles.

• Explain how attribute gages support Y14.5 requirements
• Describe the function and use of gages
• Explain the three options for gaging tolerance policies
• Describe four gage design considerations
• Describe the Y14.43 recommendations for gage allowance
• Describe the six standard classes of gagemakers’ tolerances
• Describe how tolerance stack-up affects gage accuracy
• Describe six types of functional gages
• Describe seven design constraints of functional gages
• Describe three considerations to prevent workpiece distortion during gaging
• Explain the concept of referee gaging
• Explain three areas where a departure from gage principles may be necessary
• Calculate the pin size based on the absolute method
• Calculate the pin size based on the tolerant method
• Calculate the pin size based on the optimistic method

Understand the purpose and contents of an inspection report.

• Identify what an inspection report is
• Describe five requirements of an inspection report
• Recognize the standards for reporting inspection results
• Identify three common methods for indicating inspection numbers
• Mark up a drawing to number the dimensions for inspection
• Define the term, “non-conformance report”
• Describe the contents of a non-conformance report

Understand how to inspect and report size dimensions.

• Explain the Y14.5 requirements for a feature of size
• Explain the relationship of Rule #1 and size dimension
• Describe three methods of inspecting MMC size limit
• Describe three methods of inspecting LMC size limit
• Determine number of points required for actual local size
• Compare size inspection methods
• Describe how to report MMC & LMC size inspection results

Understand how to simulate datums for inspection.

• Explain the Y14.5 requirements of datums
• Explain the effects of datum sequence on inspection
• Describe the candidate datum set concept from Y14.5.1
• Explain the effects of using the candidate datum set on inspection
• Explain how to simulate datum planes using a fixture
• Explain how to simulate datum planes using a CMM
• Explain how to simulate a datum reference frame with a functional fixture
• Explain how to simulate a datum reference frame using a CMM
• Describe how to simulate a datum reference frame from datum targets using a functional fixture
• Describe how to simulate datum reference frame from datum targets using a CMM
• Explain how to simulate a datum axis (RFS) on a functional fixture
• Explain how to simulate a datum axis (RFS) using a CMM
• Explain how to simulate a datum axis (MMC) on a fixture
• Explain how to simulate a datum axis (MMC) using a CMM
• Describe how a functional gage accounts for datum shift
• Describe how a CMM simulates datum shift

Understand how to verify form control requirements.

• Explain the Y14.5 requirements for flatness
• Describe how to verify flatness using open set-up methods
• Describe how to verify flatness using a CMM
• Describe three common practices that produce flatness measurement inaccuracies
• Explain the Y14.5 requirements straightness
• Describe how to verify straightness applied to a surface using open set-up methods
• Describe how to verify straightness applied to a surface using a CMM
• Describe three common practices that produce straightness measurement inaccuracies
• Explain the Y14.5 requirements for circularity
• Describe how to inspect circularity using open set-up methods
• Describe how to inspect circularity using coordinate measurement systems
• Describe how to inspect circularity using precision spindle systems
• Describe common sources of measurement errors for each method
• Explain the Y14.5 requirements for cylindricity
• Describe how to verify cylindricity using open set-up methods
• Describe how to verify cylindricity using a CMM
• Describe three common practices that produce cylindricity measurement inaccuracies

Understand how to verify orientation and location controls.

• Explain the Y14.5 requirements for an angular dimension
• Describe how to verify an angular dimension
• Explain the Y14.5 requirements for perpendicularity applied to a surface
• Describe how to verify a perpendicularity of a surface open set-up method
• Describe how to verify a perpendicularity of a surface using a CMM
• Explain Y14.5 requirements for perpendicularity of a feature of size (RFS)
• Explain Y14.5 requirements for perpendicularity of a feature of size (MMC)
• Describe how to verify perpendicularity of a feature of size (MMC) open set-up method
• Describe how to verify perpendicularity of a feature of size (MMC) using a CMM
• Explain the Y14.5 requirements for a position control (RFS)
• Explain the Y14.5 requirements for a position control (MMC)
• Describe how to verify a position control applied to a feature of size (at RFS) using open set-up methods
• Describe how to verify a position control applied to a feature of size (at MMC) using an attribute gage
• Describe how to verify a position control applied to a feature of size (at RFS) using a CMM method
• Describe how to verify a position control applied to a feature of size (at MMC) using a CMM method

Understand how to verify runout and profile requirements.

• Explain the Y14.5 requirements of circular and total runout
• Describe how to verify a circular runout applied to a diameter using open set-up methods
• Describe how to verify a total runout applied to a diameter using open set-up methods
• Describe how to verify circular or total runout applied to a diameter using a CMM
• Describe three common practices that produce inaccuracies in a runout measurement
• Explain the Y14.5 requirements of profile of a surface and profile of a line
• Describe how to verify a profile of a surface using open set-up methods
• Describe how to verify a profile of a line using open set-up methods
• Describe how to verify profile tolerances using a CMM
• Describe two common practices that produce inaccuracies in a profile measurement

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