Tower Malacky

Flexible consistent inspection at Porsche part supplier Tower Malacky, the Slovakian subsidiary of US company Tower, is a leading supplier of pressed parts to blue- chip motor manufacturers across Europe, such as Porsche and Volkswagen. Precision coordinate measuring machines are at the heart of the company’s rigorous quality control programmes, and a recent low-cost upgrade of these IN213 machines with Renishaw’s TP20 stylus-changing probe system has given the company dramatic benefits. This simple upgrade has saved hours of setup time and significantly improved Tower supplies many major motor manufacturers across Europe, including process repeatability. Porsche and Volkswagen Inspection of components takes place on two Renishaw’s TP20 probe system, fitted to both automatic CMMs, typically taking 3 hours CMMs, allows the stylus configuration to be to measure complex parts. Multiple points changed in seconds, with no need to requalify are taken on critical surfaces, comparing the stylus tip’s position. measured values to CAD data. The highly repeatable magnetic kinematic Benefits of stylus changing coupling allows the stylus module to simply Because of the complexity of features, virtually ‘snap’ on and off whilst ensuring the tip is every part needs both a straight and cranked accurately re-positioned. Although the ability stylus arrangement to make contact with all to swap manually between two stylus modules the specified points in one set-up (the stylus is the most basic use of the TP20, it has is the stem and ball attached to the end of the eliminated hours of manual, non-productive CMM’s probe sensor). time on an expensive automated machine. Viliam Zigo, Quality Manager, has no doubts about the importance of the probe system – “Without Renishaw’s TP20, the technicians would be constantly unscrewing and screwing in styli, spending several minutes re-qualifying the CMM each time – inspection throughput would reduce to less than half. Certain parts could not be inspected at all without changing modules.” High quality standards Finished pressed parts and other bought-in items, are all subject to sample inspection, to ensure compliance with the high tolerances demanded by their automotive customers. For each production run, 100% of the features on Computer controlled automatic CMM measuring sample a sample part are inspected on the CMMs. welded assembly, accessing every feature in one set up Case Study If this part is within tolerance, then the rest of the batch, usually thousands of parts, will meet specification. For example, 10 points are taken on a particular flange measuring 70 mm by 20 mm; if any vary from nominal position by more than 0.5 mm the part is rejected and production is halted. Flatness and form are very important, so inspection of features such as corner radiuses must be carefully controlled. Success through automation and quality Tower Malacky, based in the town of Malacky, near Bratislava in the Slovak Republic, has a long history in the supply of automotive components. At the end of 1999, the company was bought by the US company Tower and now supplies a wide range of manufacturers, including Porsche, Volkswagen, Skoda, Opel, Suzuki, and Saab. Various processes are in use in the Malacky factory - parts are pressed, sub-components are welded into assemblies and press tools are manufactured. There are 24 large presses, 20 small presses, 33 welding robots and 10 fully Viliam Zigo, Quality Manager – achieving high throughput and automated welding centres. consistent standards Tooling is fully traceable - every tool is measured on the CMMs and a quality certificate produced Each operator has to inspect their components on that proves each critical feature is within the CMMs and the upgrade to Renishaw’s TP20 tolerance. If the certificate is lost then the tool is stylus changing probe system has ensured that not used in production. this process is consistent between operators, and minimises delays. The company operates a culture of quality as an integral part of all manufacturing – there is no www.renishaw.com/CMM separate inspection department, and operators are responsible for the quality of the parts they produce. This page is intentionally left blank Renishaw plc T +44 (0) 1453 524524 F +44 (0) 1453 524901 New Mills, Wotton-under-Edge, E [email protected] Gloucestershire GL12 8JR United Kingdom www.renishaw.com About Renishaw Renishaw worldwide Renishaw is an established Australia Italy Spain world leader in engineering T +61 3 9521 0922 T +39 011 966 10 52 T +34 93 663 34 20 technologies, with a strong E [email protected] E [email protected] E [email protected] history of innovation in product development and manufacturing. Austria Japan Sweden Since its formation in 1973, the T +43 2236 379790 T +81 3 5366 5316 T +46 8 584 90 880 company has supplied leading- E [email protected] E [email protected] E [email protected] edge products that increase process productivity, improve Brazil Malaysia Switzerland product quality and deliver cost- effective automation solutions. T +55 11 4195 2866 T +60 3 5631 4420 T +41 55 415 50 60 E [email protected] E [email protected] E [email protected] A worldwide network of subsidiary companies and distributors Canada The Netherlands Taiwan provides exceptional service and T +1 905 828 0104 T +31 76 543 11 00 T +886 4 2473 3177 support for its customers. E [email protected] E [email protected] E [email protected] Products include: The People’s Republic of China Poland Thailand • Dental CAD/CAM scanning and milling systems. T +86 21 6180 6416 T +48 22 577 11 80 T +66 2 746 9811 E [email protected] E [email protected] E [email protected] • Encoder systems for high accuracy linear, angle and Czech Republic Russia Turkey rotary position feedback. T +420 548 216 553 T +7 495 231 16 77 T +90 216 380 92 40 • Laser and ballbar systems for E [email protected] E [email protected] E [email protected] performance measurement and calibration of machines. France Singapore UK (Head Office) • Medical devices for T +33 1 64 61 84 84 T +65 6897 5466 T +44 1453 524524 neurosurgical applications. E [email protected] E [email protected] E [email protected] • Probe systems and software for job set-up, tool setting and Germany Slovenia USA inspection on CNC machine T +49 7127 9810 T +386 1 527 2100 T +1 847 286 9953 tools. E [email protected] E [email protected] E [email protected] • Raman spectroscopy systems for non-destructive material Hong Kong South Korea For all other countries analysis. T +852 2753 0638 T +82 2 2108 2830 T +44 1453 524524 • Sensor systems and software E [email protected] E [email protected] E [email protected] for measurement on CMMs (co-ordinate measuring Hungary machines). T +36 23 502 183 • Styli for CMM and machine E [email protected] tool probe applications. India T +91 80 6623 6000 E [email protected] Indonesia T +62 21 2550 2467 E [email protected] Israel T +972 4 953 6595 E [email protected] RENISHAW HAS MADE CONSIDERABLE EFFORTS TO ENSURE THE CONTENT OF THIS DOCUMENT IS CORRECT AT THE DATE OF PUBLICATION BUT MAKES NO WARRANTIES OR REPRESENTATIONS REGARDING THE CONTENT. RENISHAW EXCLUDES LIABILITY, HOWSOEVER ARISING, FOR ANY INACCURACIES IN THIS DOCUMENT. © 2011 Renishaw plc. All rights reserved. Renishaw reserves the right to change specifications without notice RENISHAW® and the probe emblem used in the RENISHAW logo are registered trademarks of Renishaw plc in the UK and other countries. apply innovation, Productive Process Pyramid, Productive Process Patterns, Productivity+, AxiSet, Rengage, Trigger Logic, ToolWise, *H-5650-3080-01 Sprint, MicroHole, PassiveSeal, SwarfStop, Equator and the versatile gauge are trademarks of Renishaw plc. All other brand names and product names used in this document are trade names, service marks, trademarks or registered trademarks of their respective owners. Part no. H-5650-3080-01-A.

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