This video introduces Hexagon's new Maestro metrology system, designed to revolutionize Coordinate Measuring Machines (CMMs) by addressing long-standing industry challenges. Developed from a "ground zero" approach, Maestro focuses on user personas and key pain points: the scarcity of skilled operators, the need for adaptable equipment in changing production environments, the demand for increased productivity, and the drive towards greater autonomy and seamless integration within manufacturing workflows. The system is presented as an all-digital, high-speed solution featuring intelligent automation, "no-code" programming via a digital twin, a "smart machine eye" camera for diagnostics, and standardized connectivity (e.g., MQTT). Ultimately, Maestro aims to transform CMMs from "necessary evils" into integrated, high-OEE (Overall Equipment Effectiveness) assets that contribute to more efficient, lights-out manufacturing by minimizing bottlenecks and simplifying operations for a broader range of users.
Revolutionizing Metrology: Hexagon's New Maestro System
0:00 Introduction & Context: The hosts introduce Mike's self-proclaimed nickname "Maestro of Manufacturing" and set the stage for a major announcement from Hexagon's Manufacturing Intelligence division, emphasizing their broad integration of hardware and software beyond traditional metrology.
2:25 Quality as a Bottleneck: The discussion highlights that quality control, particularly CMM operations, often becomes a bottleneck in manufacturing processes, despite being critical for delivering quality parts on time.
3:36 Guest Introductions: Sean Thielen (Product Sales Manager for Stationary Products at Hexagon, 29 years experience) and Yorg Deler (General Manager for Stationary Measurement Devices and Machine Tool Measurement at Hexagon, Germany, 17 years in metrology) are introduced.
6:16 Defining Stationary Metrology: Stationary metrology involves bringing the part to the measurement device (too heavy to carry around), contrasting with portable metrology where the device is brought to the part.
6:55 The Genesis of Maestro: Hexagon developed Maestro by starting "from ground zero," questioning how a CMM would be designed today if it didn't already exist, to address persistent customer challenges.
Expertise Shortage: Lack of highly skilled CMM operators.
Adaptability: Need for equipment to handle frequently changing part designs and production requirements.
Productivity: CMMs are often too slow, hindering overall process speed.
Autonomy: Desire for systems that reduce operator influence, increase speed, and integrate seamlessly into production workflows.
10:52 Persona-Driven Development: Maestro's development was based on understanding and serving five user archetypes: the traditional "white collar" metrologist, the majority "supervisor and operator," the "all-rounder" in small/medium enterprises, and the "automation/production guys" who prioritize seamless integration without needing to be metrology experts.
14:29 Voice of the Customer: Direct feedback from customers and sales teams, who often view CMMs as a "necessary evil," was crucial in shaping Maestro's features to address real pain points.
15:52 CMM as a "Necessary Evil" at Hill: Mike confirms his company's experience, where the CMM is primarily used for required first-article inspections rather than integrated into daily workflows, largely due to a lack of specialized training.
19:55 The Importance of Integration: The goal is to make CMMs a desired, integrated part of the manufacturing process, rather than an external, bottlenecking step, enabling a more holistic approach to quality.
21:18 CNC-like CMM & All-Digital Solution: Maestro aims to bridge the gap between CMM and CNC machine tool workflows, operating as an all-digital system designed for speed, ease of use, connectivity, and adaptability.
Workflows: Designed to be intuitive and similar to machine tool operations.
Bi-directional Connectivity: Shares data with MES systems and other devices using industry standards like MQTT, making integration easier.
Increased Uptime & Robustness: Engineered for higher reliability than traditional CMMs.
No-Code Programming: Utilizes a digital twin, allowing automatic generation of inspection programs from CAD data (with PMI), tailored to specific machines and sensor sets.
"USB of Metrology": Active components like sensors and racks automatically identify themselves to the system, simplifying setup.
28:50 Enhancing Overall Equipment Effectiveness (OEE): Maestro's integration capabilities aim to improve OEE (Availability x Performance x Quality) by providing traceable data, enabling better planning, and allowing centralized management of CMM capacity across multiple sites.
Smart Machine Eye Camera: Automatically records machine activity and errors, aiding remote diagnostics and support, akin to a "dashcam."
Significant Speed Increase: Outperforms previous models by 25-30% due to optimized design, reduced processing pauses, and continuous 5-axis movements.
38:35 Facilitating In-Process Inspection and Automation: Maestro simplifies the integration of CMMs into automated "lights-out" manufacturing systems, making it easier to achieve self-correction and optimized production flows.
41:59 Availability: Maestro was unveiled at the Control show in Germany on May 6th. Orders will be accepted from mid-June at Hexagon Live (June 16-19 in Las Vegas), with deliveries to follow.
43:18 Key Takeaway: Maestro is hailed as a "game changer" that will eliminate inspection bottlenecks, driving greater efficiency, connectivity, and adaptability in the manufacturing industry, ultimately enabling shops to produce more parts faster.