Metrology is of fundamental importance to future factories because so much factory efficiency relies on accurate data. A process or product cannot be improved unless it can be measured accurately. Metrology, the science and processes of measurement, captures data about both tooling and components to allow new manufacturing processes – such as additive manufacturing and robot-operated machining – to be tested and perfected.
It can help process high volumes of data to make better decisions about 'standard' but gradually improving manufacturing processes, like milling and turning. The role of metrology in accelerating smart factories is underestimated, with much of the 'Industry 4.0' dialogue focused on robots and automation.
Measurement increases productivity while reducing waste and cost in manufacturing through improved control of production processes and more effective verification of components and final products. Consider 'Industry 4.0' as a catchall to describe disruption in how things are being made, to improve speed, accuracy, flexibility and customisation.
Design engineers used to design, make, measure, discover errors then remake something. New 'generative engineering' models allow a designer to describe what they want to make and the programme tells him/her the best way to revise the design, for manufacturability and cost.
Simulation and better digital twins allows a manufacturing engineer to design and test the productivity of a new line or machine in the digital world before a dollar is spent on a prototype or new machine. This is making the physical prototype redundant.
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