Solving the ‘Goldilocks’ Problem: A Just-Right Assembly Solution

In the old children’s fable Goldilocks and the Three Bears, Goldilocks found one bowl of porridge too hot and the other too cold; but Baby Bear’s was just right. One bed was too hard and the other too soft; but Baby Bear’s was just right … you know how the rest of the story goes.

That story reflects the partnership between Laser Projection Technologies (LPT) and Delta Sigma Company (DSC): Alone, their solutions bring particular strengths; but together, they are a just-right solution for high-precision manufacturing environments.

Powerful collaboration

LPT and DSC have been working industriously to create a dual solution that combines the strength of each to make a powerful tool that isn’t available elsewhere in the industry. Engineers from both teams are harnessing the strength of the laser and tapping into the flexibility of the DSC’s ProjectionWorks projection system to streamline and improve speed and quality on the toughest projects in aerospace, maritime, heavy equipment, military, and heavy vehicle manufacturing.

Just how are these two systems working together?

• Laser projectors provide a small amount of high-accuracy data. LPT lasers are extremely accurate; they pinpoint a location within 0.005 of an inch. They also have small spot sizes and high resolution. When pressed, they tend to flicker; in addition, as line length grows, visibility becomes more difficult, as the laser appears dimmer.[br][br]Laser projectors provide the accuracy and detail needed in complex assemblies.

• Optical projectors provide a large amount of lower-accuracy data. DSC’s ProjectionsWorks optical projector has the benefits of unlimited color and text, solid-filled areas, and pictures — and the projection is always bright. However, the optical projector is not as accurate as the laser because it employs a larger pixel size.[br][br]Optical projectors automate workflow when work is long, complex, and variable.

As you can see, the strengths and limitations of the two technologies are almost perfectly complementary. That’s why DSC and LPT began working together to find a just-right solution. When the two systems are combined, customers will have access to an unprecedented capability to project work instructions and positional layout information to aircraft mechanics and assembly technicians in a way that’s never been done before.

Better benefits, better value

The new, fully integrated visual manufacturing solution has numerous applications that are just right for the industry.

• First, when out-of-station work must be performed, the usual tools may not be available. With the use of the laser and optical projection system, this out-of-station work can be made much less painful by the application of 3-D projections with an accuracy of 0.005 of an inch.

• The system helps eliminate rework by providing technicians the images and instructions they need to complete the job the right way, the first time. This is possible because the dual system provides better and more exact instructions and placement, so everything operators need to know is right in front of them at the exact moment they need to know it, leaving very little room for error.

• This system also provides a way for technicians to self-check their own work, verifying the job as they go, rather than at the end when changes are much harder to make.

When there are fewer errors and less need to rework projects, manufacturers will achieve a higher level of product uniformity and quality, even for very complex assemblies.

While neither laser nor optical projections are perfect on their own due to system limitations, the combined technologies are just right together.

[cta]For answers to more questions about reducing or avoiding rework in your environment, call DSC at (770) 575-5100 or email info@deltasigmacompany.com.[/cta]