This video introduces Hexagon's new "Maestro" solution, a groundbreaking stationary metrology system developed to modernize Coordinate Measuring Machines (CMMs) and address long-standing challenges in manufacturing quality control. Designed from the ground up, Maestro aims to transform CMMs from traditional bottlenecks into integrated, autonomous, and highly efficient components of the production workflow. Key innovations include an all-digital architecture, a no-code programming environment leveraging digital twins, enhanced bi-directional connectivity with manufacturing execution systems (MES), significant speed improvements, and smart diagnostics via an integrated camera. The system prioritizes ease of use for a broader range of operators, facilitates seamless integration with automation, and provides crucial data for achieving true Overall Equipment Effectiveness (OEE) in modern factories.
Maestro: A New Era for Manufacturing Metrology
0:00 A Manufacturing Bottleneck: The hosts discuss the common issue of quality control, particularly CMMs, being a bottleneck in manufacturing processes.
1:12 Hexagon's New Offering: The episode introduces Hexagon's "Maestro," a new solution for stationary metrology, with guests Sean Thielen and Jörg Deler from Hexagon.
6:05 Reimagining CMMs: Hexagon developed Maestro by designing a CMM from scratch, addressing the fact that CMM technology hasn't fundamentally changed in 40 years.
7:38 Key Challenges Addressed: Maestro tackles major industry pain points:
Expertise Shortage: A global lack of highly skilled metrology operators.
Lack of Adaptability: Traditional CMMs are not designed for frequent part changes.
Slow Productivity: CMMs are often seen as slow, hindering overall production speed.
Limited Autonomy: Need for systems that reduce human influence and integrate with workflows.
10:52 User-Centric Design: Development involved identifying five distinct user archetypes (expert metrologist, supervisor/operator, all-rounder, automation/production managers) to ensure the system serves diverse needs.
19:00 CNC-Like CMM: Maestro aims to bridge the gap between CMM and machine tool operations by creating a "CNC-like CMM" with standardized, intuitive workflows and improved connectivity.
All-Digital Solution: Focuses on speed, ease, connectivity, and adaptability for future growth.
Bi-directional Connectivity: Seamless integration with MES and other systems via industry standards like MQTT.
Improved Uptime: Designed for enhanced robustness and provides data on Mean Time Between Failures (MTBF).
No-Code Programming: Uses a "digital twin" to automatically generate inspection programs from CAD data (with Product Manufacturing Information - PMI), reducing manual programming effort.
25:55 Simplified Setup: Maestro features a "USB of metrology" approach, where active components (sensors, racks) are automatically identified and configured, greatly simplifying setup compared to traditional manual processes.
28:47 Driving OEE: By providing accurate quality data, Maestro helps manufacturers calculate and improve Overall Equipment Effectiveness (OEE = Availability x Performance x Quality), moving beyond "vanity metrics" like spindle utilization.
On-Machine Display: Provides real-time status and alerts.
Smart Machine Eye Camera: Records machine activity and triggers recording on errors, aiding diagnostics and remote support.
Increased Speed: Outperforms previous models by 25-30% through optimized movements and reduced processing delays.
38:35 Automation Integration: Maestro's standardized interfaces (e.g., MQTT) make it easier to integrate into automated systems for in-process inspection, enabling potential self-correction or diversion of faulty parts, crucial for "lights out" manufacturing.
42:05 Availability: Maestro was revealed on May 6th at the Control show in Germany. Orders will be accepted from Hexagon Live (June 16-19th in Las Vegas), with deliveries commencing thereafter.
43:55 Key Takeaway: Maestro's focus on integration, ease of use, and a common language across manufacturing processes is expected to be a "game changer," helping shops overcome inspection bottlenecks and achieve more efficient and effective production.