Darmstadt, Germany – MAFO Systemtechnik AG, a specialist in contract manufacturing and integrated manufacturing solutions, has recently introduced Visometry’s augmented reality solution Twyn for visual quality inspection.
The solution allows employees to compare physical components directly against their CAD data. The impact has been immediate: MAFO now completes inspections faster, detects more deviations, and documents its quality processes more easily.
MAFO supports customers across the full production process, from design and manufacturing to the assembly of complete modules and systems. With foundry operations, welding, machining, painting, and assembly all under one roof, the company produces a wide range of components and assemblies for customers across many industries. Its portfolio spans everything from small precision parts to welded structures several meters in size. Small batch sizes, high product variety, and frequent product changes make it difficult to standardize inspection processes in the same way as in series production.
More Efficient Quality Inspection with Augmented Reality
MAFO’s high level of vertical integration and broad product variety place particular demands on quality assurance. Before Twyn was introduced, visual inspections involved comparing physical components with CAD models on a computer, with additional 2D drawings used where needed. Inspectors had to move back and forth between the component, the screen, and the drawing. For complex assemblies and welded structures in particular, this made visual inspection extremely time-consuming.
With Twyn, MAFO has been able to reduce inspection times. Employees now perform the visual comparison directly on a single iPad instead of constantly switching between the component, computer screen, and drawing. “Users can learn the basics of Twyn in around 30 minutes and start working with it almost immediately. That is one of the reasons why Twyn is now an integral part of our daily quality inspection,” says Manuel Mayer, Quality Director at MAFO Systemtechnik AG.
MAFO now uses Twyn across several visual quality inspection processes, including operator self-inspection in production, incoming goods inspections for sheet metal and welded parts, outgoing goods inspections, and first article inspections.
Using Visometry’s AR solution, quality inspectors compare physical components directly with their CAD data on an iPad. Twyn overlays the digital twin onto the physical component in real time. “The real value lies in the overlay. It makes deviations immediately visible – quickly and easily,” explains Manuel Mayer.
Twyn also fits seamlessly alongside MAFO’s existing measurement systems. High-precision dimensional inspections, such as concentricity, parallelism, and form and positional tolerances, continue to be carried out using coordinate measuring machines. Twyn is used wherever fast visual quality inspection delivers the greatest value, for example to identify missing components, incorrectly positioned welded parts, or obvious deviations. At the same time, the solution helps inspectors decide whether a more detailed inspection with a coordinate measuring machine is required.
Faster Inspection Results, Lower Costs
Twyn delivers the greatest benefits with complex assemblies, large components, and externally sourced welded structures. The solution helps quality inspectors identify potential defects early on, such as missing threads, incorrectly positioned welded parts, or missing individual components. The parts inspected range from just a few centimeters to several meters in size. For large components in particular, Twyn offers a major advantage: inspections can be carried out directly on the production floor, without transporting the parts to a separate inspection area.
MAFO’s inspectors are also detecting more defects than before. With Twyn, even deviations that have not yet affected production can be identified early and eliminated proactively. This significantly reduces rework and transport costs. Twyn has also made quality inspection documentation easier. Because MAFO handles such a wide variety of products, inspection checklists tend to become longer and longer over time. Instead of continuously expanding these checklists, MAFO can now simply document that a CAD-assisted visual quality inspection has been carried out.
Press contact
Alberto Castiglioni
Head of Marketing
Phone: +49 6151 155 274
Email: alberto.castiglioni@visometry.com
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