When furnishing a lab, a successful project installation is the result of users who know what they want to accomplish, and consultants and manufacturers who know how to listen and place customer requirements first. Going into any job of this scope, it’s beneficial to have a clear direction, yet the flexibility to allow the realities of space, functionality and costs to shape final decisions.
AMO applied this same diligent approach to sourcing equipment to furnish their WaveFront Sciences lab and manufacturing facility in Albuquerque, N.M. This facility develops and manufactures the iDesign portion of the iLASIK system. iDesign is the WaveFront aberrometer that produces three-dimensional eye mapping for generating the corrective prescriptions used in the iLASIK laser correction procedure.
It’s not surprising that with the level of sophistication in the WaveFront aberrometer that they would look for similar qualities in the equipment with which they’re manufactured. In setting up their new lab, AMO’s Keith Ratté, CrystalWave and ClearWave product manager, was tasked with creating a completely new assembly and test environment.
Ratté’s first decision was to furnish the lab with modular workstations rather than built-in casework. "We introduced a new generation of products with the expectation of growth and change. We want our lab flexible to accommodate future enhancements," he says.
So why not just pick an equipment manufacturer and begin ordering? The short answer is limited knowledge. The difference in lab furnishings, even among products offered by one vendor, is subtle and often confusing. A consultant experienced in facility design and workflow efficiency can help avoid costly errors and provide faster solutions. Kieser brought a thorough knowledge of the modular workstation capabilities and installation needed to shape a plan, and bridged communications with IAC.
IAC states their mission as improving the organization, function and atmosphere of their customers’ production and assembly work areas, inspection stations and research labs. IAC approaches this mission through such innovations as multi-part extruded aluminum uprights used on their D4 workstations, a unique power distribution system (PDS), and assurance of maximum usability.
While Ratté asked questions about various equipment vendors, IAC sent back their own questions.
This is obviously a critical time. If vendors aren’t questioning you, you probably aren’t being taken seriously. Questions about space, physical requirements of the assembly product, operator motion, material transfer and ergonomics of the work flow must be asked and answered to achieve the most productive end.
During this process, several preconceived notions on how the assembly cells would function were jettisoned. The customer, consultant and supplier worked together solving critical details. Dave Verrill, IAC’s application support manager, coordinated planning for the AMO project. After review with AMO, Kieser sent Verrill layouts with countless notes.
"When you read through Kieser’s notes you know that no details were overlooked," says Verrill. Several rounds of reviews took place. Everything from workstation size, storage, power, materials and even colors were reviewed. Responsiveness proved key with Kieser and IAC quickly turning around revisions and engineering reviews to allow AMO to stay on schedule.
So why did AMO choose the D4 workstations? It began with configurability. The D4’s modular design allows single- or double-sided workstations to be linked together in various configurations: straight lines, or L- or U-shaped cells. AMO chose to use two modified U-shaped cells to accommodate their workflow. "As manufacturing volume and testing requirements increase, we can easily add more cells and expand those in place," says Ratté. "The D4’s modularity makes this a simple process." In addition, the D4 offers ESD protection that’s essential for AMO’s critical electronics assembly.
The next factor was versatility. Extruded aluminum uprights provide the D4’s main structural support. They feature continuous vertical channels into which worksurfaces, shelving, cabinetry, lighting and other accessories are secured in infinite combinations. "We can change the heights on any of the worksurfaces and shelving as needed. When we need more surface area, we just add another shelf to the uprights," says Ratté.
But the D4’s PDS "sealed the deal" for Ratté’s selection. The PDS supplies three separate 20-A electrical circuits to outlets positioned on the uprights within a complete cell grouping with special duplex outlets numbered 1, 2 or 3. These snap into any of the outlet positions on the D4 uprights to tap into a respective-numbered circuit.
At 60 days from completion, Ratté knew what was needed and how the new equipment would serve its purpose. Kieser had confidence that they matched the equipment to AMO’s needs. And IAC developed manufacturing plans, including custom-engineered components, and pre-identified and solved issues for AMO’s requirements.
With the final decisions made and the order placed, IAC’s customer service personnel hammered out the final details. Color choices were confirmed; shipping and arrival dates of the equipment to AMO were planned. Drawings for the custom-engineered components were sent to AMO for final approval. Communication with the customer throughout the manufacturing process ensured no surprises.
With arrival of the workstation components for the two cells, the process was passed to AMO’s Bill Finley, senior optical technician, for final assembly. Finley has broad assembly experience, so the two cells presented no problems. He notes that even those with less experience would not find this assembly difficult.
As a bonus, Ratté also states, "They look nice, too!" He adds that AMO customers often visit the iDesign lab, and the D4 workstations present a clean appearance that matches AMO’s design philosophy.
Ultimately, selecting the correct workstation protects your lab from future circumstances that could make your investment obsolete. "It’s important to have the configurability to handle today’s manufacturing and testing needs while retaining the flexibility for future updates," says Ratté.
For additional information, contact:
David Verrill, Sales Application Manager, IAC Industries, 817-540-3085, dverrill@iacindustries.com, www.iacindustries.com/4.
