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When a manufacturer assures its customers that parts will meet or exceed expectations, be delivered on time, and conform to all requirements and specifications, the first time, last time, every time, it is clear that quality control is a top priority. At Component Engineers Inc. (CEI) in Wallingford, CT, achieving these high-quality standards requires continuous improvement of processes to stay ahead of the ever-evolving and increasingly demanding customer requirements and expectations. From the quoting stage through to final delivery, CEI is committed to meeting all requirements and specifications as defined by its customers. Moreover, CEI embraces complex manufacturing challenges that few others are willing to take on — making quality control (QC) not just a requirement, but a cornerstone of its business.

Component Engineers Inc. (CEI) was founded in 1980 and is currently led by second-generation owner Ron Hansen Jr., employing 80 people across two shifts in a 52,000-square-foot manufacturing facility. The company provides a wide range of manufacturing solutions, from small to high-volume production runs, including fabricated tubing, custom parts and assemblies, tooling and die design and build, and laser marking for critical applications across the medical, dental, aerospace and defense, automotive, firearms, energy, and commercial industries. CEI leverages technologies from stamping, CNC Milling, Mill-Turn, Swiss Turning, Wire EDM, and custom-built machinery to meet stringent customer specifications. The company applies Lean and Six Sigma practices and maintains certifications including ISO 9001:2015 and ISO 13485:2015, and is compliant to AS9100D, IATF 16949:2016, and ITAR. With tolerances as tight as ± 0.0001 inch, CEI ensures process and product quality using advanced methodologies such as PPAP, Verification, Validation, and/or Qualification (VVQ), Gage R&R or MSA, capability studies, SPC, FAIs, and other inspection activities, to name a few.

The Need for Improvement

"We’re seeing increasing demands for quality control data from our customers," said Eric Boyea, quality manager at CEI. "We are verifying results using Starrett vision systems with 2D optical and 3D touch probe capabilities, optical comparators, hand gages, and layout inspections to correlate measurements. However, some of our inspection methods were too time-consuming and complex. Quality is always evolving and to remain competitive, CEI must also evolve with the times." The time came for CEI to explore new inspection technology at the 2023 EASTEC trade show (now named MT Series East). With an eye on modernizing and simplifying inspection processes, particularly for larger and more complex parts, CEI ultimately chose to continue its two-decade relationship with Starrett, reaffirming its confidence in the brand’s technology, service, and support.

Time to Upgrade: CEI Chooses Starrett AV450 Vision Systems

After evaluating several systems, CEI acquired two Starrett AV450 Automatic Vision Systems in November 2024, with installation and calibration completed in December 2024. Installed in a newly remodeled and 6S’d quality lab, the investment was partially supported by Connecticut State grant funding and aligned with CEI’s continuous improvement initiatives.

The Starrett AV450s feature an expansive 450 x 350 x 200 mm (17.7" x 13.8" x 7.8") measuring envelope, making it ideal for large, repetitive part inspections or high-throughput operations. Its high-resolution zoom optics, computer-controlled quadrant (LED) ring lighting, and MetLogix M3 software allow for precise, fast, reliable programmable measurements. "The Starrett AV450 is easy to use and delivers the advanced features we needed," Boyea said. The Starrett AV450 and MetLogix M3 software supports both 2D optical and 3D touch probe measurements, and offers powerful features such as the following, to name a few:

• Using a .dxf file for comparison of PROFILE against perfect profile per ASME Y14.5-2018
• Easy-to-apply GD&T parameters to measurements per ASME Y14.5-2018
• Frame stitching for large parts
• Palletizing for multi-part inspections in an "X" & "Y" grid configuration
• Automatic pattern recognition for seamless execution of part program

Training for Long-Term Success

Training was performed by Applied Measurement Solutions, a Starrett authorized representative, through weekly sessions over a two-month period. CEI’s five-member quality control team quickly adapted. "Two of our inspectors, who had never programmed parts before, created and executed inspection routines on the Starrett AV450s as part of their training," said Boyea. "We awarded certificates to acknowledge their success."

Real-World Benefits and Customer Impact

The Starrett AV450 systems have been integrated into daily manufacturing and inspection routines. CEI now delivers faster, more reliable data—particularly for profile measurements using imported .dxf files. "The Starrett AV450 eliminates some of the painstaking tasks," said Boyea. "With the older systems, profile segment measurements were slower and more prone to errors. The Starrett AV450 gets it right the first time, in a fraction of the time." The Starrett AV450 also optimizes incoming and final inspection activities where sampling is required, allowing entire sample sizes of parts in a row and column format (palletizing) to be measured simultaneously, improving throughput and accuracy. CEI estimates that inspectors now complete additional inspections daily, significantly increasing productivity.

"The Starrett AV450s enhance our ability to meet rising customer demands for data-rich, high-accuracy inspections," said Boyea. "And we’re also implementing a new ERP system by year-end to further strengthen traceability and process controls."

Looking Ahead

As CEI continues to grow, the Starrett AV450 Vision Systems are key to maintaining the company’s high standards. "These systems expand our inspection capabilities and support future equipment upgrades, especially with the consistency offered by the MetLogix M3 software," said Hansen. "We will benefit from the MetLogix M3 software that is integrated across Starrett’s metrology equipment, by having a unified, familiar software platform going forward," Boyea added.

Validation for Accuracy, Repeatability, & Reproducibility

Quality software used to process, store, and/ or retrieve quality data for the purpose of making a pass/fail decision in a product, process, and/ or a quality metric must be verified, validated, and/or qualified (VVQ) per ISO 9001:2015, ISO 13485:2016, AS 9100D, and IATF 16949:2016 standards. Validation is required where the resulting output cannot be verified by subsequent monitoring or measurement. CEI developed and completed internal VVQ activities based on the standards it is certified/compliant to for its new and legacy Starrett systems, including MetLogix M3, Heidenhain QC5000, and Heidenhain IK5000 software. These activities were completed in February 2025, ensuring that all of the Starrett Vision Systems yield accurate, repeatable results when used in decision-making. "Our VVQ strategy is built around the 6Ms of production strategy: Man, Machine, Material, Method, Measure, and Milieu (Environment)," Boyea explained. "We created the VVQ plan, executed and performed the installation, operational, and performance qualifications, and summarized the VVQ, demonstrating that when the five Starrett Vision Systems, including the legacy systems and new AV450’s, are operated as intended under normal operating conditions, they yield accurate results within stated requirements," said Boyea.

Conclusion

"CEI has trusted Starrett since the early 2000s," said Ron Hansen Jr. "They are more than a supplier; they are a strategic partner, now and for the foreseeable future."