What is a “Metrologist” anyway?Steven StahleyDirector of measurement Excellence, Cummins Inc.

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Metrologist Defined…Wikipedia

Performs Metrology work involving precision measurement and comparison of physical quantities such as mass, length, time, force, speed, voltage and current. They calibrate precision equipment which measures these physical units. They may also certify that outside standards of such quantities as mass and volume are correct.

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Metrologist Defined…Agilent

Develops and evaluates calibration systems that measure characteristics of objects, substances, or phenomena, such as length, mass, time, temperature, electric current, luminous intensity and derived units of physical or chemical measure. Identifies magnitude of error sources contributing to uncertainty of results to determine reliability of measurement process in quantitative terms. ..Directs engineering, quality and laboratory personnel in design, manufacture, evaluation and calibration of measurement standards, instruments and test systems to insure selection of approved instrumentation. …

Cummins Confidential

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The Metrologist Role

But…do you have to have someone titled a Metrologist to do this work?

Or

Will someone with the right skills do?

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Paradigm Shift

Focus less on developing Metrologist and more on developing Metrology skills…

At Cummins Metrology skills can be utilized through out our manufacturing and business processes.

The most effective way to improve our processes is to get the right skills into the hands closest to the process.

In our plants we would rather have the manufacturing associates, technicians, engineers etc have the Metrology skills related to what they are doing then depend on one Metrologist to try to provide those skills.

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6 Sigma Project - Objective and Deliverables Decrease the educational gap in Metrology to

increase the percentage of qualified employees (exempt and non-exempt) in the manufacturing and engineering entities.

Qualifiers– Technical skills where focused on Dimensional

Metrology, as Cummins processes are dependent on length.

– Areas of focus• Manufacturing• Product development• Service

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6 Sigma Project Phase I Phase I Deliverables:

– Consolidated Skill Set (specifically in Metrology) required for technicians and engineers

– Perform an Educational Gap Analysis with local Columbus Indiana schools in the subject of metrology.• Indiana University, Purdue University, Columbus (IUPUC)• Purdue College of Technology (PCOT)• Ivy Tech Community College (ITCC)• Local High Schools

– Identify curriculum improvements• Resources• Professor qualifications• text books, etc.)

– Generic template to identify educational gap in other disciplines

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Skill vs.. Level

Skills and Definitions

Levels 0 to 4

How do we get there?

Compile master skill set in metrology for engineers and technicians

Survey manages, engineers, technicians, etc as to current and needed skills levels

Review current university/HS curriculum and perform a gap analysis

Recommend revisions to the curriculum that satisfy the skill set needed to do the job.

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6 Sigma Project Phase II Phase II Deliverables:

– Utilize Consolidated Skill Set defined in Phase I– Perform an Educational Gap Analysis with a broader set of

schools, focusing on a sample of schools from which Cummins recruits engineers• Purdue Mechanical School of Technology West Lafayette• Penn State• Ohio State University• University of Kentucky

– Identify curriculum improvements• Resources• Professor qualifications• text books, etc.)

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What do we already have?

Top 25 skills for engineers Generic Template (created in first project) Internal Cummins Skills Assessment

How do we get there?

Put list together for top 5 technical schools co-located in our manufacturing sites

Review current university curriculum and perform a gap analysis

Recommend revisions to the curriculum that satisfy the skill set needed to do the job.

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Deliver Skill Gap Analysis

University Liaisons at CMI were contacted to retrieve the proper contact information for the universities

Contact was made with the universities to gauge their interest

Once the universities were onboard, the gap analysis worksheet was shared with them.

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Summery of Results (Results Key)

Yes Skill is being taught at correct proficiency level, no modification needed

YesSkill is being taught at correct proficiency level, but need additional CMI resources

YesSkill is being taught but not at correct proficiency level, needs further modification in curriculum

NoSkill is not being taught, needs further modification in curriculum and/or resources

No Skill not required to be taught

Key

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Summery of Results (Sample)

Measurement Data Analysis Yes Yes Yes No

Taught at proficiency level of 2 in Stat 3450, which is a mandatory course in BSME.Required PL = 2.7Steve to send some documentation to ensure it is covered.

Taught at proficiency level of 3 in IE 323, which is a mandatory course in B.Sc Ind.& Mfg. Engr.Required PL = 2.7

Taught at proficiency level of 2.5 in 310/311/505, which are mandatory and elective course in B.S.M.ERequired PL = 2.7

Can add to MET/MFET 590 (NEW). Need case studies and technical assistance from CMI. Dual level which can be taken by senior or grad level courses. This is an elective course.Required PL = 2.7

Geometric Dimensioning & Tolerancing

Yes Yes Yes Yes

Taught at the proficency level of 1 in course 2900 and profiency level of 2 in course 5680, which are both mandatory and

Taught at the proficency level of 3 in course IE 305 which is mandatory, part of B.Sc Ind.& Mfg. Engr.Required PL = 2.3

Taught at the proficency level of 1.5/2.5 in courses 205/507 which are mandatory/elective, part of B.S.M.E. Need

Taught at the proficency level of 2 in courses MET102 which is a mandatory course, part of BSMET/MFET Need

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Summery of Results (Sample)R&R Studies No Yes Yes Yes

Required PL = 2.6Steve to send references to what R&R is to reassess, and MBA handbookMay fit in well in an Industrial Engineering course (Jose Castro)

Taught at the proficiency level of 4 in course IE 424 / 436 which are electives in B.Sc Ind.& Mfg. Engr. Required PL = 2.6

Taught at the proficiency level of 1 in course 311 which is a mandatory course in B.S.M.E. Additional modifications can be integrated in 251/310/311. Need lab experiments from CMI. Steve to help provide examples (Cummins trainings and examples)Required PL = 2.6

Taught at the proficiency level of 2 in course MET 451 which is an elective course in BSMET/MFET.Required PL = 2.6

Measurement Uncertainty Analysis

Yes Yes Yes Yes

Taught at profiency level of 2.2 in ME 3870 which is a mandatory course in BSMERequired PL = 2.6

Taught at profiency level of 3 in IE 305 which is a mandatory course in B.Sc Ind.& Mfg. Engr. Required PL = 2.6

Taught at profiency level of 2.5 in 310/311/505 which is a mandatory course in B.S.M.E. No additional modifications needed. 251 is a new lab course and need funds for last set of equipment. UK to provide list of equipment and parts and Steve to check how much CMI can help.Required PL = 2.6

Taught at profiency level of 1 in MET 245 which is a required course in BSMET/MFET. Changes can be made in MET/MFET 590 (NEW) at a proficiency level of 2. Need case studies and technical assistance from CMI. Required PL = 2.6

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Summary of Curriculum Changes

Curriculum proposals for each skill have been proposed by the universities

Follow-up with each school on their proposals to ensure the changes are made and any resource requirements are met.

Control Plan: – Every 5 Years update gap analysis– Update School contacts– Review resource needs– Re-Survey Cummins Managers, Engineers and technicians

to see if skills are improving.

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Lessons Learned

Not all Universities will be interested in initiatives like this, even if it will benefit them long-term

Universities that are not local to Columbus are not as likely to make curriculum changes

Difficult to find the correct contacts if the university is not local

Schools really liked the level of detail of the request! Process created in Phase I of project works well with

other schools as well (not just local)

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QUESTIONS / COMMENTS

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