Precision in Practice

Challenge

A tier-1 aerospace supplier needed a complete FAI program for complex turbine blade and vane geometries with tight GD&T callouts, requiring NIST-traceable CMM inspection and AS9102-compliant documentation.

Solution

IIS developed a custom CMM inspection routine, implemented Metbase for data management, and delivered a fully documented FAI package meeting AS9102 requirements. Cycle time was reduced by 40% versus the customer's prior approach.

Key Results

• →40% reduction in inspection cycle time
• →100% AS9102 compliance
• →Repeatable CMM program implemented in Metbase
• →First-pass acceptance rate improved to 98%

Challenge

A defense contractor required precision-machined titanium housings for sensitive electronic assemblies, with tolerances to ±0.0005", full ITAR compliance, and complete dimensional traceability documentation.

Solution

IIS machined the titanium components on our multi-axis CNC centers, performed 100% CMM inspection, and delivered Metbase-backed traceability documentation packages meeting ITAR and AS9100 requirements.

Key Results

• →±0.0005" tolerance achieved across all critical features
• →ITAR-compliant documentation package
• →Zero non-conformances on 200-unit production run
• →Full CMM traceability in Metbase

Challenge

A multi-site industrial manufacturer was struggling with inconsistent paper-based inspection records, difficulty sharing data between sites, and lengthy audit preparation. They needed a scalable inspection data solution.

Solution

IIS implemented Metbase across three facilities, migrated historical inspection records, trained quality staff, and configured automated reporting for routine compliance documentation.

Key Results

• →Eliminated paper-based inspection records
• →Audit preparation time reduced by 65%
• →Real-time data sharing across 3 sites
• →Standardized reporting templates deployed

Challenge

A machined bracket family was experiencing high scrap rates and inconsistent dimensions. The customer needed engineering support to identify root causes and develop a robust production process.

Solution

IIS conducted a thorough process audit, redesigned the machining approach including tooling and fixturing, implemented SPC tracking, and validated the new process through a production run with 100% CMM inspection.

Key Results

• →Scrap rate reduced from 18% to under 2%
• →Consistent dimensional results across 500-piece run
• →Process documented and transferred to customer
• →SPC data captured in Metbase

Challenge

A government maintenance depot needed CMM inspection support for legacy equipment components with incomplete or non-digital drawings. Full NIST traceability and documentation were required.

Solution

IIS digitized legacy drawing requirements, developed CMM inspection routines, and delivered comprehensive inspection reports with NIST-traceable data and Metbase storage for future reference.

Key Results

• →100% inspection documentation delivered
• →Legacy components digitized and cataloged
• →NIST-traceable calibration chain maintained
• →Reusable CMM programs for future inspections