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The GM Casting Engine and Transmission Center started using their first ThermoFit Pro modules in June of 2011. The new product line enables GM to build up even the most complex stylus system using the CALYPSO stylus simulator without the need for typical custom designing in CAD. Generic angle blocks can be modified in the software to the desired angle by simply choosing the according angle values. The real angle blocks are then quickly manufactured from semi-finished parts. The finished angle blocks can be machined either by ZEISS or if desired by their own tool shop, as the semi-finished parts are available from stock. Each piece gets a ZEISS part number for easy documentation and reordering. No CAD engineer or drawing is needed and everything can be done by their own application engineer within the Stylus System Creator. “I‘m very impressed with the development of the CALYPSO simulation and Stylus System Creator using ThermoFit Pro modules,” says Craig Wegienka, seni- or manufacturing engineer at GM Casting Engine & Transmission Center. “I was able to use the Stylus System Creator to create the entire set of block and head tooling for our project. I simulated each individual probe configuration in CALYPSO to verify the tooling. The simulation proved that all tooling would work correctly.” The library of the Stylus System Creator contains more than 1,200 different styli, extensions and connecting elements, plus additional tools to create virtually every kind of custom probe tooling. With the help of different sized cubes and bars, even the most complex system can be designed and built quickly. ThermoFit Pro modules have plug-in connections instead of threads to help avoid angle distortions when exchanging worn styli. Even whole branches of the stylus systems can be exchanged without having to readjust angles. GM has about 13 sets of ThermoFit Pro tooling, each with approximately 15 different configurations. “All of these options and the ease of use reduce our probe tooling design and manufacture time by about 40 percent,” states Craig. “It saves us not only time, but also money because we don’t have to scrap probe components when there are changes.” The task for GM to guarantee reproducibility of their products by having the same quality results - regardless if the parts come from a plant in Bangalore, Shanghai, Detroit or Sao Paolo - is a big challenge as varying employee skill levels or the availability of spare parts can cause production delays. And product design changes require program and probe tool modifications along with documentation changes. GM can now rely on the ThermoFit Pro modules and the CALYPSO Stylus System Creator to globalize quality control programs, reduce product launch time, while also quickly adapting to any product changes. Reproducibility of the products guaranteed by identical quality levels. Carl Zeiss Industrial Metrology, LLC Contact: +001 (763) 744-2409 6250 Sycamore Lane Minneapolis, MN 55369 USA Publication in Quality Magazine on 3rd August 2012 “We not only save time but also money, because we no longer need to dispose of stylus system components if there are changes.” Item 35