How Optomech’s Optical Profile Projector Transformed Precision Measurement for a Leading Automotive Manufacturer

 

In the highly competitive automotive industry, precision and accuracy in component measurement directly impact product quality, safety, and compliance with global standards. One of Optomech’s customers, a Tier-1 automotive supplier, was facing recurring quality control challenges. Manual inspection methods were proving inconsistent, leading to dimensional errors, increased rejection rates, and delays in production.

To overcome these issues, the company turned to Optomech’s Optical ProfileProjector—a trusted solution for dimensional metrology across industries like automotive, aerospace, die & mould, and medical devices.

The Challenge

The customer’s inspection team relied heavily on calipers, micrometers, and traditional gauges for measuring complex parts such as gears, cams, and threaded components. While effective for basic checks, these tools were inadequate for:

• Complex geometries – Intricate profiles were difficult to verify manually.

• Operator dependence – Results varied depending on the skill and focus of the inspector.

• Time inefficiency – Each part required multiple manual measurements, slowing down throughput.

• Inconsistent accuracy – Subtle deviations often went undetected, resulting in rejections during later assembly stages.

The cost of rework, coupled with customer complaints, highlighted the urgent need for a more reliable, precise, and efficient measurement system.

The Solution

After evaluating several alternatives, the automotive supplier selected Optomech’s Optical Profile Projector, Model PP 400H—a horizontal projector designed for heavy and shaft-like components.

Key reasons for the choice included:

• High-Resolution Telecentric Lenses – Delivering distortion-free images with magnification from 5x to 100x.

• Advanced Illumination – Collimated halogen light for sharp profile measurement and fiber-optic cold light for surface inspection.

• Digital Readout with Metrology Software – Allowed for easy measurement of points, lines, arcs, circles, and angles, with direct integration to CAD for reverse engineering.

• Optical Edge Detector – Reduced operator subjectivity and improved consistency in results.

• Heavy-Duty Stage with Motorized Movement – Ensured stability and ease of measuring large shaft components.

This solution offered the perfect balance between optical performance, accuracy, and operator-friendly design.

The Results

Within three months of implementation, the customer reported significant improvements:

• Inspection time reduced by 40% – Faster measurement cycles enabled higher production throughput.

• Rejection rates dropped by 30% – Early detection of dimensional deviations minimized downstream failures.

• Enhanced measurement accuracy – High-resolution encoders ensured precise readings traceable to NABL standards.

• Improved consistency – The Optical Edge Detector minimized human error, providing repeatable results across shifts.

A quality manager from the company remarked:
“The Optomech Optical Profile Projector has completely transformed our inspection process. What earlier took 15 minutes per part is now completed in under 9 minutes, with far greater accuracy. This has boosted our confidence in meeting global OEM standards.”

Why Optomech

The customer chose Optomech not only for the product’s performance but also for the company’s:

• 42+ years of expertise in optical metrology and machine vision.

• End-to-end support, including installation, operator training, and after-sales service.

• Customization capabilities, offering models tailored for flat parts (vertical) as well as shafts and larger components (horizontal).

• Trusted reputation across aerospace, automotive, and medical manufacturing industries.

Conclusion

This case study demonstrates how Optomech’s Optical Profile Projector helped a leading automotive supplier streamline quality control, reduce rejection costs, and achieve precise measurements with confidence.

For manufacturers in automotive, aerospace, die & mould, and medical devices, investing in an Optical Profile Projector is more than a quality initiative—it’s a competitive advantage.

👉 Ready to transform your measurement accuracy? Explore Optomech’s range of Optical Profile Projectors today and discover how we can support your precision manufacturing journey.