In its optimum form, Six Sigma is anything but simple or practical. Given its considerable upfront cost and ongoing complexity, it’s best viewed as a results-driven expedition of Homeric scope, one where the final destination is 3.4 defects per million opportunities. It’s not a journey for the faint-hearted. You must be seriously committed to pursuing it for the long term, or you’ll never recoup your sizable upfront investment, let alone enjoy a net return.

The quality industry offers a number of terrific events during the course of the year, but none is more informative, entertaining, and intimate than the Coordinate Metrology Systems Conference. This year’s CMSC occurs in Charlotte, North Carolina, July 21 through July 25. As always, the event is packed with activity, including a bustling exhibition hall, unique off-site events (a tour of Richard Childress Racing is included this year), and white paper presentations demonstrating the latest advances in portable coordinate metrology.

When Gabe Draguicevich was asked to help fabricate a titanium hip implant based on CT (computed tomography, also known as CAT) scan data, he had to coordinate numerous technologies to complete the project. Because the CT data consisted of 2-D cross-sections, Draguicevich had to stack and align the individual scans to create a 3-D model, which he used to create a polygonal mesh in the form of a stereolithography (STL) file. After creating a prototype, he had to verify it against the original scan data, which was no mean feat considering that software capable of providing deviation analysis of the model surface to the STL file did not exist. Finally, Draguicevich created a wireframe model from the STL mesh to machine the final product. The entire process took approximately two weeks to complete.

That was 20 years ago. According to Draguicevich, “If I had the tools that are available today, I could have simply taken the CT scan data and created the STL mesh in one step, and then machined directly from the mesh. The data-processing capabilities of modern software have made the entire process painless compared to years past. Furthermore, I could have taken the finished piece and inspected it for accuracy using the original scan data as the reference. Any deviations could have been addressed by modifying the finished part in coordination with the inspection process.”