Optimising Production with Accurate Jigs and Fixture Assembly
In manufacturing, the difference between an efficient, profitable production line and one hit by delays often comes down to precision. Jigs and fixtures are essential tools in this process, holding components in place or guiding tools to ensure each part is created to exact specifications.
For businesses seeking reliable, repeatable results, the accuracy of jigs and fixtures is non-negotiable. The use of advanced metrology technologies are a huge advantage in this area. It also requires the right set of toolmaker skills, combined with the relevant knowledge of hardware and software.
In this article, we explore how precise jig and fixture assembly can optimise production lines, reduce waste, and improve product quality.
Why jigs and fixtures matter
Jigs and fixtures play a pivotal role in both manual and automated manufacturing environments. Fixtures hold workpieces steady, ensuring they remain in a fixed position, while jigs guide cutting or drilling tools to ensure consistency in operations. Without accurate jigs and fixtures, parts may end up misaligned, affecting the functionality and quality of the final product.
In sectors such as aerospace, automotive, and medical device manufacturing, precision is paramount. A small deviation can lead to costly consequences, including product recalls, potential safety risks, and production downtime. In high-stakes environments, accurate assembly of jigs and fixtures can determine a company’s reputation and competitive edge.
The role of metrology in jig and fixture assembly
Ensuring the precision of jigs and fixtures has traditionally involved skilled manual inspection and tooling. However, advances in metrology have changed the game. Technologies including laser trackers, structured light scanners, and coordinate measuring machines (CMMs), enable manufacturers to measure complex geometries with a degree of accuracy unattainable by traditional methods.
In jigs and fixtures assembly, metrology tools allow manufacturers to ensure consistency. 3D scanning and measurement tools capture highly accurate data, ensuring that each jig and fixture is identical to the next. This level of consistency is vital for companies producing high volumes, or parts that require tight tolerances. They also significantly reduce waste. This is because with precise assembly, fewer components fall short of specification. This is not only cost-effective but aligns with sustainability goals, by minimising material use and waste output.
Accurate jigs and fixtures ensure that production setups are quicker and smoother too. By using 3D metrology to measure and verify these tools, manufacturers can reduce the need for constant adjustments, streamlining production. 3D measurement tools also allow for ongoing verification that assists in quality control. They provide early insights into any potential misalignments or wear in jigs and fixtures. This capability allows manufacturers to carry out predictive maintenance, reducing the likelihood of unexpected downtime.
Improving manufacturing efficiency with 3D verification
High-quality jigs and fixtures are essential, but they don’t guarantee flawless production by themselves. By integrating metrology into the assembly process, you can achieve proactive quality assurance, reducing error rates and improving the overall efficiency of the production line.
For example, an automotive manufacturer will use jigs to assemble various components. By employing laser trackers or portable CMMs to regularly verify the positions of these jigs, operators can immediately identify and correct any deviations from the intended design.
This process eliminates small inaccuracies that, if left unchecked, could lead to larger, costlier problems later in production. The result is a smoother workflow, fewer interruptions, and a more reliable product.
Key considerations for jig and fixture accuracy
While the benefits of accurate jig and fixture assembly are clear, there are some key considerations to bear in mind when integrating 3D metrology into this process. The materials used should be stable and durable, to withstand repeated use and potential environmental changes, such as temperature fluctuations. Materials prone to wear or deformation will impact alignment over time, potentially negating any initial precision.
Regular calibration of both the jigs and fixtures themselves, as well as the metrology equipment, ensures ongoing accuracy. A proactive approach to calibration can catch issues early, reducing the risk of disruption. The training, skills and experience of teams should also be prioritised. Metrology tools require skilled operators who understand the intricacies of both the equipment and the assembly process. Investing in comprehensive training or partners means making the most of these technologies and interpreting results accurately.
Look to the future with 3D Solutions
As manufacturing continues to advance, the demand for precision will only increase. For industries where accuracy is vital, integrating metrology into jigs and fixtures assembly informs a forward-looking strategy. This approach ensures that you can maintain stringent quality standards, reduce waste, and improve production processes.
The choice to invest in precision is an investment in long-term operational efficiency, product quality, and brand reputation. Whether for a small batch or mass production, accuracy sets a high standard for modern manufacturing, enabling you to deliver reliable, high-quality products with consistency and confidence.
Our skilled team at 3D Solutions have worked with multiple disciplines of measurement, in sectors including automotive and aerospace. Our extensive knowledge and experience means we can carry out a variety of tooling installations on any scale, meeting the highest standards.
Get in touch today to speak to one of our team about your next project.
