Tofaş is a car manufacturer established in 1968 in Bursa (Turkey), where the plant is located. The company manufactures passenger cars and light commercial vehicles. Today it is one of the largest manufacturers in this sector and, with some 7,000 employees, it has an annual production capacity of 450,000 vehicles.
Tofaş manufactures Fiat Egea compact sedan models, hatchbacks and station wagons in its factory in Bursa. Marketed under different model names and brands worldwide, Tofaş's Egea range is sold as Fiat Tipo in Europe and as Dodge Neon in Mexico. Alongside the manufacture of passenger and commercial vehicles for FIAT and RAM as part of the new Doblò project, Tofaş sells six brands (Fiat, Fiat Professional, Alfa Romeo, Jeep, Maserati, Ferrari) in Turkey. In 2020, Tofaş exported 118,000 vehicles to 80 countries and the company accounts for 19% of total car production in Turkey.
The main activity of the unit in Bursa is currently the manufacture of the Fiat Egea car and the Fiat Doblò utility vehicle, both in floor cab versions short or long wheelbase. It currently produces nearly 1,000 vehicles per day, which requires a dedicated metrology team to ensure the stability of geometries in relation to processes and products.
The measurement team at Tofaş uses different Hexagon metrology equipment, including 3 CMM Global. These systems were installed in 2016, in combination with Hexagon's PC-DMIS inspection software and are used in particular to assess the quality of small parts supplied by third parties. The team also has two Bravo HP CMMs, one with four arms and the other two. The first version is used as part of a blank box diagnostic system, and the second to perform statistical process control measurements in relation to the Fiat Egea model.
While these systems have provided excellent results, the Tofaş measurement team has turned to digitization systems to take advantage of the great advantages offered by contactless measurements. This revolution began with the Hexagon white light system used to check the closing elements. This one was also installed in 2016 and is associated with the CoreView software.
The latest metrology equipment is a fully automated inspection cell, based
on the Absolute Tracker and Leica T-Scan 5 measurement technology, which is used to measure commercial vehicles made in Bursa. Established in 2020 and commissioned by PolyWorks inspection software, the cell has proven its effectiveness and seems to be at Tofaş only the beginning of a process of automating control solutions.
"Instead of a CMM, we use scanning technology, and it offers many advantages ," says Utku Erdem Kaynar, director of the metrology laboratory at Tofaş in Bursa. "It allows us to see many areas and parts of the vehicles."
" We use it in particular to measure white boxes and closing elements, with characteristics such as surfaces, adjustment lines, nuts, slots, holes. All parts associated with the white box can be easily raised with these systems. As far as tolerances are concerned, it depends of course on the measurement applications, but we deal with sheets. The minimum tolerance is therefore ± 0.4 mm and the maximum tolerance is ± 2 million meters. This varies of course depending on the size of the area. »
Tofaş's measurement staff was impressed not only by the quality of Hexagon's metrology equipment, but also by the competence of the local team in Turkey, who assisted them in the planning and implementation of numerous inspection projects.
" We work closely with Hexagon Turkey," says Recep Boylu, measurement center administrator at Tofaş. " The employees are highly qualified and skilled at solving problems and proposing solutions tailored to our needs. And they are of course responsive in maintenance, which reduces the downtime of our equipment. Now we exclusively use Hexagon products, both in the field of CMMs and scanning systems. Previously, we had used various machines from other metrology manufacturers, but due to the problems with after-sales service and maintenance, we abandoned them and now we are focusing entirely on Hexagon's solutions, with which we also benefit from excellent support. »