Harwin, based in Portsmouth, is a manufacturer of electrical and electronic connectors, supplying customers across aviation, aerospace, medical and general industry. Having started in 1952 as a turning house, the business has grown to employ 300 people at its main manufacturing site, serving sectors that all demand the highest quality.
Harwin has invested in six OGP SmartScope multi-sensor metrology machines over the past ten years. These have allowed them to automate inspection across the shop floor, cutting inspection times from 10 to 15 minutes per component down to 1 to 2 minutes in many cases, while removing the variability of manual measurement.
Project Brief:
Supplying safety critical connectors to aerospace, medical and industrial customers, Harwin needed inspection that was fast, consistent and free from the variability of manual methods.
Richard McDonnell, Electroplating Process Engineer at Harwin, explained:
“Manual measuring techniques, by their very nature, can be inconsistent. The human element will always introduce some variability, and those problems led us to look at some automation in our measuring. Some dimensions are very, very difficult to measure by hand.”
Harwin first encountered OGP UK at an exhibition at the NEC.
“We saw you at an exhibition, the NEC, some years ago. We liked what we saw, so we purchased our first SmartScope 200 and really liked the piece of equipment. We find it easy to program, easy to use for our operators, and we quickly found areas across the facility where we would benefit from more of the machines.”
The Solution:
Harwin has invested in six OGP SmartScope multi-sensor metrology machines, a mix of SmartScope CNC 200s and CNC 300s, some fitted with touch probes and some running optics alone, positioned across the shop floor.
The SmartScope CNC range is a high capacity benchtop multi-sensor measurement system, combining optics, lasers and probing in one machine to handle parts that traditional inspection methods cannot reach.
Jamie Luxford, Junior Process Engineer at Harwin, explained how the multi-sensor capability fits their work:
“We make use of the OGP’s multi-sensor technology. We use both camera probing and touch probing, which allows a lot of flexibility. It allows us to touch on all kinds of measurements if we need to, ensuring that quality for our customers is there.”
With Harwin’s components being very small, the optical performance has proved essential. Richard explained:
“The majority of our components are very small, so optics was needed in every case. Lighting is also very, very important, with each component reflecting light in a different way. With a good optics and lighting set up, components are much, much easier to measure.”
Jamie also highlighted the impact of ZONE3 software on their most demanding drawings:
“One of the benefits of the OGPs and the ZONE3 software is the geometric dimensioning and tolerancing, and how easy it is to do in the software. A lot of our drawings require that as a critical dimension, and doing that with manual methods is obviously very difficult. It can be done within a matter of seconds, as opposed to something that may have taken a matter of minutes before. That has allowed us to speed things up significantly and saves us multiple hours every week.”
The Benefits:
Investing in OGP multi-sensor metrology machines has transformed Harwin’s approach to inspection, delivering speed, consistency and the confidence to inspect more often throughout every manufacturing run.
Richard explained the impact on inspection times:
“It’s taken an inspection from probably 10 or 15 minutes per component down to 1 or 2 minutes in many, many cases.”
Jamie pointed to the wider gains once programs are written:
“Once those programs are done, it allows operators from all across the factory to run those programs, to check their parts and see how they’ve been written. Based on some previous time studies, those checks are up to five times quicker.”
Richard described what that consistency means for quality:
“It’s installed consistency and a high level of confidence that the components are being measured and inspected to a correct standard. By automating our inspection techniques, we not only inspect much quicker, much faster, but we’re able to inspect much more often throughout any manufacturing run. This increases our quality and, indirectly, is going to reduce costs.”
The results have driven repeat investment over a decade:
“We purchased our first one 10 years ago. It was so successful that we’ve gone on to purchase five more, just based on the amount of time it saves and the reduction in variability,” said Richard.
With Harwin expanding considerably and building a new facility that doubles their manufacturing space, the machines have made further investment an easy decision.
“It’s never difficult to justify capital expenditure for a new machine in another department, because we’ve seen the benefits with the machines that we already have. I would never hesitate with purchasing another OGP,” he added.
“I’d have no problem with recommending OGP to anybody who wants to invest. We’ve had a great experience with no issues, no problems. The equipment is repeatable, reliable, and it’s always there working when we need it. They don’t fail, they don’t break down.
“I know all of the staff fairly well because I’ve been dealing with them for quite some years, and I think they know me. They know how to win and they know what’s important to us. I see our relationship continuing for many years to come.
“OGP has changed our approach to inspection. It’s taken us to the next level. I wouldn’t go back.”
Why OGP UK?
OGP UK provides the best-in-class multi-sensor measurement systems, combining optics, lasers, rotaries and probes for unrivalled performance in the quality control of manufactured parts and components.
OGP UK is part of the Carfulan Group who specialise in providing the most advanced manufacturing technologies available, helping customers across their five divisions to achieve optimal performance and end-product excellence.