Solving the Final 5% of Production Precision
Achieving consistent precision in high-volume manufacturing is not always about major process changes. Often, the biggest gains come from solving the final 5% of variability.
In swim goggle production, small inconsistencies in lens marking and handling created quality challenges. Manual processes introduced variation, especially at high speeds. As a result, production teams needed a reliable way to improve consistency without slowing output.
Collaborative robots from Universal Robots provided a practical solution. They delivered repeatable performance while integrating directly into the existing workflow.
System Overview
Application: Laser marking and part handling
Robot: Universal Robots collaborative robot (cobot)
Operation: Continuous, high-precision production
Result: 7+ years of reliable, non-stop operation
This system combines precise motion control with consistent part positioning. The cobot ensures each component is handled the same way, every cycle. This level of repeatability helps eliminate variation in marking quality.
The Challenge
Manual handling created small inconsistencies in positioning. Over time, this led to variations in marking quality. At high volumes, even minor deviations impacted overall product consistency.
Maintaining speed while improving precision was the key challenge.
The Solution
The cobot introduced consistent, repeatable motion into the process. It handled each part with the same positioning and timing on every cycle.
As a result, the system achieved:
• Consistent marking quality across all parts
• Reduced reliance on manual adjustments
• Continuous operation without performance drift
• Improved overall process stability
The cobot operates safely alongside existing equipment. It integrates without requiring major changes to the production line.
Conclusion & Next Steps
This application highlights how automation can solve small but critical process gaps. By addressing the final 5% of variability, manufacturers can improve quality without sacrificing throughput.
Collaborative robots offer a flexible way to introduce precision into existing workflows. They are well-suited for tasks that require repeatability, consistency, and long-term reliability.
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