Why Engineers Benefit from Understanding Metrology
Through the application of science, technology and mathematics, engineers provide solutions to real-world problems. But why is metrology, the science of measurement, so critical and how does it benefit engineers?
In this article, we will examine the application of metrology in engineering and explore its role within the engineering world.
Basis for Metrology
Early in school, we learn about measurement because it is a skill we will use throughout our personal lives and careers. This is especially true in engineering, whose excellence hinges on the ability to measure and quantify with accuracy and precision. From the initial design concepts to the final manufactured product and its subsequent maintenance, measurements are taken at every stage of the engineering lifecycle.
Metrology serves as the foundational discipline of accuracy and precision, underpinning the overall quality of design and production. Its principles and applications are not confined to a single engineering domain but are relevant in every industry. It is vital to safety-critical sectors such as nuclear, aeronautical and medical.
Originating from the basic human need for standardised units, particularly for trade and commerce, the field of metrology has evolved into a scientific discipline with global collaboration. Agreement on standards and practices underpins economic development. Today, metrology facilitates trade and commerce, scientific research and development, manufacturing and engineering, as well as safety and reliability.
Application of Metrology
Engineering critically depends upon key metrology principles to ensure that innovation and quality can proceed optimally without interference from poor or absent measurement. By using accuracy to ensure a measurement is close to its true value and precision to ensure repeatability, engineers can apply their knowledge and skills to innovation and production with the control, validation, and verification needed to minimise errors, waste, and costs. Of course, basic metrology encompasses more than these terms. Some other terms benefiting engineers include:
- Traceability, which is essential for linking measurements back to reference standards.
- Tolerance defines the acceptable range of variation for a component.
- Error uncertainty, which identifies and quantifies measurement uncertainties, allowing for more reliable engineering decisions.
- Root cause analysis, which helps pinpoint non-conforming features and deviations from design specifications, enabling corrective actions and preventing recurring errors.
When it comes to innovation, engineers apply their knowledge to solve problems for society’s benefit. Engineering design is a discipline in which metrology enables engineers to formulate solutions with less guesswork, verify assumptions, and validate work. Today, engineers can use technology to simulate designs digitally before producing a prototype and then entering production. This would be impossible without metrology.
During manufacturing, metrology ensures that produced parts meet the stringent specifications detailed in engineering designs. Regular quality checks, both during and after production cycles, also ensure output passes quality assurance and that any quality problems are recognised and rectified as quickly as possible. Interventions usually require ad-hoc measurements. This makes metrology critical to manufacturing cost-effectiveness and profitability.
A variety of metrology tools, ranging from basic instruments like callipers and micrometres to more advanced technologies such as coordinate measuring machines (CMMs) and optical comparators, are employed to ensure that product characteristics, including dimensional accuracy and surface quality, are within specified tolerances.
The production process relies heavily on metrology to deliver the quality control described above. Without this ability, production costs would be higher, output volumes would be lower, and economies would not be as healthy. As an engineer, being able to investigate problems, provide solutions and contribute to quality discussions is essential. Understanding metrology will enable an engineer to measure, interpret readings and translate them into solutions and effective communication for other stakeholders in the business.
While the act of measuring values is invaluable, engineers also benefit from a metrology process known as calibration. Calibration ensures measuring equipment remains accurate by comparing it against known standards and ensuring decisions about product quality are based on reliable data. Without proper calibration, the risk of accepting defective products or rejecting good ones in production increases. Calibration traceability is also essential, ensuring the engineering team knows all factors that affect a measurement.
Safety and Reliability
Safety and reliability are two key characteristics that engineers frequently address. Society depends on them for well-being and economic wealth. For any engineer, the phrase safety-critical should prompt a different mindset, where designs, procedures and processes are tightened in favour of safety. This applies to sectors such as aerospace, medical devices, and nuclear power. As mentioned in previous blog posts, any error in the measurements of one component in a complex system, such as an aeroplane or nuclear power station, can have devastating consequences for many people. For this reason, metrology is also tightened through policy in these sectors. Metrology training, documentation of measurements, adherence to standards, traceability and auditing are expected not only for engineering excellence but also for regulatory and legal compliance.
Regulatory and Legal Compliance
Many industries have stringent regulations regarding measurement accuracy and traceability; a solid grasp of metrological principles helps engineers meet these requirements. Legal metrology, which ensures the accuracy of measurements that affect trade, health, safety, and the environment, underscores the importance of adhering to established standards. A strong understanding of metrology also supports compliance with quality standards, such as those established by the International Organisation for Standardisation (ISO), ensuring product reliability and customer satisfaction.
Career Progression and Success
Lastly, engineers are employed for their knowledge and skills. Understanding metrology and having the ability to practice and communicate the discipline will help an individual progress in their engineering career, offering invaluable skills important in nearly every facet of engineering – especially in safety-critical sectors.
Jeff Eley is Chairman and Managing Director of Eley Metrology Ltd, a Derby-based specialist in precision measurement and quality assurance. With decades of experience in metrology, he has helped develop and supply advanced measuring equipment, granite metrology standards and tailored solutions for demanding engineering applications.
