Iris Optics
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Manufacturing TestMachine Vision

Manufacturing Optical Inspection Bring-Up

Turning a measurement concept into a deployable manufacturing inspection workflow.

Confidentiality & Anonymization Note

These examples are generalized and anonymized to illustrate Iris Optics capabilities. Details are modified to protect confidentiality and avoid disclosure of proprietary employer, client, or product information.

Challenge

This example illustrates bridging the gap between a successful lab prototype measurement and a reliable, high-volume manufacturing inspection station.

Approach

We define clear Critical-to-Quality (CTQ) metrics, optimize sensor, optics, and lighting selection, perform rigorous Gage R&R studies, and develop Standard Operating Procedures (SOPs) while aligning vendors and integrators.

Outcome

This methodology establishes a robust test method and clearer production readiness, eliminating major bottlenecks 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 can prove unreliable as a product transitions from R&D to New Product Introduction (NPI). If a lab setup is highly sensitive to alignment and ambient light, false-reject rates on the pilot line can become unacceptably high, requiring the measurement system to be ruggedized for mass production.

The Approach

We utilize a systematic approach to ruggedize inspection stations:

  1. CTQ Definition: We clarify the exact Critical-to-Quality metrics that the station needs to control, separating them from “nice-to-have” lab data.
  2. Hardware Optimization: We overhaul the optical train, selecting robust sensors, telecentric optics, and stable illumination sources less sensitive to part presentation variation.
  3. Gage R&R: We conduct rigorous Gage Repeatability and Reproducibility studies to characterize measurement system variation and ensure it is a fraction of the total part tolerance.
  4. Deployment & SOPs: We create clear Standard Operating Procedures for calibration and operation, and align equipment integrators on final specifications.

The Outcome

This approach can achieve a dramatic reduction in false rejects and cycle time, giving the manufacturing team a robust, reliable test method and clearing a major hurdle for a product’s successful launch into mass production.