Cummins uses Surfcom 5000 advanced contour and surface measuring machines and Rondcom 60 form measuring machines from Carl Zeiss Pty Ltd to measure tiny precision parts for leading-edge technology fuel systems used in diesel engines.
The XPI common rail fuel system is manufactured by Cummins-Scania XPI Manufacturing LLP, a 50-50 joint venture company located at the Cummins Fuel Systems facility in Columbus, Indiana, and at the Cummins plant in Juarez, Mexico.
According to Spencer Wilkison, XPI Quality Manager at Cummins, the Carl Zeiss measuring machines allow them to measure in real-time and more frequently, reducing their work in progress.
The accuracy and frequency of the measurements are critical factors for Cummins that designs and manufactures advanced fuel systems for diesel engines.
Following comprehensive evaluation of Carl Zeiss measuring machines in 2006, and based on the measurement results, service and support, Cummins decided to purchase three Rondcom and five Surfcom machines. As part of its capacity expansion starting in the spring of 2008, the company phased in an additional five machines, including one GageMax coordinate measuring machine.
Wilkison explains that precision grinding is required for their components with multiple grind operations producing the final print features or critical in-process features. After each operation, the operators perform all of their own measurements with the data being sent to SPC to control processes and review monthly production capability.
Key benefits of Carl Zeiss measuring machines:
- Zero customer rejects related to any precision grinding features
- Reduced scrap quantity
- Reduces time required for Pre-Production Approval Process (PPAP) relative to new part and machine introduction
- Easy-to-use TIMS software allows operators to run an automated program for part measurement
- Automation increases accuracy by eliminating operator error during setup
- Reliability and robustness ensures trouble-free operation almost 24 hours a day over three shifts