The Client
Doughty Engineering Ltd, based in Ringwood in the United Kingdom, specializes in the manufacture of lifting, suspending and rigging equipment for the entertainment industry. The company serves theaters, film studios and event venues, maintaining high standards of quality and precision.
Analysis of the Problem
The laser marking system previously used by Doughty Engineering had significant limitations in terms of production throughput. The complete cycle for marking 140 components took nearly 4 hours, creating a bottleneck in the production line that impacted overall lead times.
The inefficiency was mainly due to:
- High cycle times per single component
- Downtime during loading/unloading operations.
- Limited process automation
Implemented Solution
After conducting a detailed analysis of the production process and related productivity calculations, LASIT Laser UK proposed the implementation of the Helios X-Y-Z system with dual-table configuration.
System Technical Specifications:
X-Y-Z Movement System
- Servo-controlled axes with high dynamics
- High positioning accuracy
- Optimization of marking paths
Dual-Table Configuration
- Two independent work stations
- Simultaneous marking at loading/unloading
- Elimination of handling downtime
Control and Software
- Customized operator interface
- Automatic production sequence management
- Monitoring of process parameters
Operational Results
The implementation of the Helios system generated the following quantifiable improvements:
Time Parameters
- Cycle time: Reduced from 240 minutes to 40 minutes for 140 pieces
- Throughput: 500% increase over previous system
- Machine utilization: Continuous production without downtime
Qualitative Parameters
- Improving the consistency of markings
- Reducing process variability
- Increased repeatability of operations
Customer Feedback
Mark Chorley, Director of Doughty Engineering, commented on the implementation:
“We are satisfied with the quality, accuracy and productivity improvement offered by the Helios system provided by LASIT Laser. The installation, commissioning and training were conducted professionally and thoroughly.”
Implementation Methodology
The project was developed following an engineering approach structured in three consecutive phases. The initial analysis phase involved an in-depth study of the existing production process through time-motion analysis and mapping of operational flows, allowing precise identification of bottlenecks and quantification of the expected ROI. Subsequently, the design phase defined the technical specifications of the system, including customization of the control software for integration with existing operational protocols and detailed planning of integration methods to minimize the impact on current production. The final implementation phase included mechanical and electrical installation activities, complete commissioning of the system with verification of operating parameters, technical training of operating personnel, and final validation of performance through production testing under real-world conditions.
Technical Considerations
The success of the implementation was determined by several factors:
- Thorough analysis of requirements: Detailed understanding of specific production requirements
- Appropriate technical solution: Selecting the optimal configuration for the application
- Effective integration: Minimization of impact on existing operations
Conclusions
The Doughty Engineering case demonstrates how in-depth technical analysis and selection of the appropriate laser solution can generate significant improvements in production efficiency. The results obtained represent an industry standard benchmark for this type of application.
Experience confirms the importance of a methodical engineering approach in the evaluation and implementation of laser marking systems for industrial applications.