Iris Optics
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Manufacturing TestMachine Vision

Manufacturing Optical Inspection Bring-Up

Turning a measurement concept into a deployable manufacturing inspection workflow.

Challenge

The client needed to bridge the gap between a successful lab prototype measurement and a reliable, high-volume manufacturing inspection station.

Approach

We defined clear Critical-to-Quality (CTQ) metrics, optimized sensor, optics, and lighting selection, performed rigorous Gauge R&R studies, and developed Standard Operating Procedures (SOPs) while aligning vendors and integrators.

Outcome

The project resulted in a robust test method and clearer production readiness, eliminating a major bottleneck in the NPI process.

Background

Developing a new optical measurement technique in the lab is only half the battle. Deploying that technique to a factory floor halfway around the world, where it must be operated by technicians 24/7, requires a different level of rigor.

The Challenge

A critical optical inspection step was proving unreliable as the product transitioned from R&D to New Product Introduction (NPI). The lab setup was highly sensitive to alignment and ambient light, and false-reject rates on the pilot line were unacceptably high. The client needed to ruggedize the measurement for mass production.

The Approach

We took a systematic approach to ruggedize the inspection station:

  1. CTQ Definition: We clarified the exact Critical-to-Quality metrics that the station needed to control, separating them from “nice-to-have” lab data.
  2. Hardware Optimization: We overhauled the optical train, selecting more robust sensors, telecentric optics, and stable illumination sources that were less sensitive to part presentation variation.
  3. Gauge R&R: We conducted rigorous Gauge Repeatability and Reproducibility studies to prove that the measurement system variance was a fraction of the total part tolerance.
  4. Deployment & SOPs: We created clear Standard Operating Procedures for calibration and operation, and aligned the equipment integrators on the final specifications.

The Outcome

The modernized inspection station achieved a dramatic reduction in false rejects and cycle time. The manufacturing team gained a robust, reliable test method, clearing a major hurdle for the product’s successful launch into mass production.