Scaling efficiently: Inspection Efficiency
Rapid expansion and the complexity of its products, puts a company on the search for a real-time data solution.
Since 1989, Thorlabs Inc., a leader in the photonics industry, has been instrumental in pioneering advancements in the science of light and optics. The Newton, New Jersey, company’s extensive range of products, from intricate optomechanical components to sophisticated nanotechnology systems, cater to a diverse clientele in scientific, industrial and educational sectors. However, Thorlabs’ rapid expansion and the complexity of its products presented significant challenges in maintaining production efficiency.
Thorlabs’ products are at the cutting edge of photonics, including optomechanics, lasers, fiber optics and advanced imaging systems. Each product, whether it’s an optical detector used in a research lab or a precision laser for industrial applications, demands meticulous manufacturing. This complexity necessitates a manufacturing process that is both precise and adaptable to the evolving needs of the photonics industry.
With more than 90 machine tools spread across more than 9,290 sq. m (100,000 sq. ft.) of production space, Thorlabs struggled with operational inefficiencies. Its existing process, heavily reliant on manual data collection, was inadequate for the growing scale and complexity of its operations. This inefficiency led to delayed problem identification and resolution, directly impacting production throughput and quality.
In the company’s quest for a more efficient manufacturing process, Thorlabs embarked on a trial implementation of MachineMetrics Inc.’s production monitoring and analytics platform. This platform from the Easthampton, Massachusetts-based company was tested on 10 machines to evaluate its effectiveness in a real-world environment and get a feel for how the system works with various machines. The trial’s success led to a full-scale deployment, reportedly marking a significant shift in Thorlabs’ manufacturing approach.
The integration of MachineMetrics brought about a substantial improvement in machine utilization rates, nearly doubling previous figures. This was a significant gain, considering the high-value and precision-oriented nature of Thorlabs’ products. The platform provided real-time data insights, revealing lower-than-expected utilization rates and highlighting areas for process optimization.
Thorlabs reports that MachineMetrics enables operators to see the direct impact of their inputs on production efficiency. Image courtesy of MachineMetrics“>
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