A first-time gear manufacturer was facing a massive 90% rejection rate on their
production line. They were stuck. The importance of Critical to Quality parameters in
gear inspection such as Total Composite Error (TCE), OD Runout, Radial distance,
and Rolling were not properly addressed by the team. Each mistake led to more
rework, more delays, and growing financial losses. Unsure where to turn and
hesitant to invest in a solution they didn’t fully understand, they reached out to
CalibroMeasure.
The quality team at a renowned gearbox manufacturer was frustrated
and overwhelmed. Inconsistent gear quality from vendors, coupled with
error-prone manual roll testing, led to painfully high rejection rates. Day
after day, they watched financial losses helplessly. With no clear solution
in sight, the team had reluctantly accepted the issue as normal.
Here's why the team was losing confidence day by day
Lack of Inspection Knowledge:
They didn’t know about critical parameters like TCE and OD runout.
High Rejection Rates:
90% of their production was being rejected.
Hesitant to Invest:
They feared spending money on something uncertain.
Huge Financial Losses:
Every rejected batch added to their losses.
GearMate: A 90% Drop in Rejections and Full Confidence Restored
CalibroMeasure guided the client through each step. Start small
was the mantra. Client procured the Gear Master to build
confidence. After seeing how GearMate handled critical
inspections like TCE and OD runout, the client’s trust grew, and
they fully invested in GearMate.
Results
Rejection Rates Reduced by 90%
All-In-One Inspection:
GearMate handled everything from rolling accuracy to OD runout, radial distance in one system.
Real-Time Feedback:
The team now had instant insights to make quicker adjustments.
Trust in the System:
GearMate earned their trust, transforming how they approached gear production.
GearMate: The Solution for Faster,
Accurate Gear Inspections
Key benefits of Measuremate
Industry 4.0 ready features like
Gear Tester Data saved against QR code and transferred in real time to server.
Process operation
Setting gear tester process made so easy that an unskilled operator can do it.
PDI reports
Automatic and instant PDI reports for gear inspection process.
Ensure TCE detection
Nick detection feature detects gears making noise even when TCE/TTE are within the tolerance span.
Zero rejection
GearMate calculates and compensates the “master runout” for ensuring zero rejection skipping to customer
