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A leading manufacturer of precision turned components for the Indian automotive and EV supply chain was struggling to keep pace with rising inspection demands. With over 1,200 part numbers — shafts, bushings, pins, and aluminium extrusions — their quality team relied on manual micrometers, vernier calipers, and optical comparators. Each part required 8–12 individual measurements, taking 4 to 6 minutes per component. As OEM requirements tightened to ±10 µm tolerances, inspection became the production bottleneck. Gauge R&R studies were marginal at 24%, and there was no SPC data export to the plant ERP. An estimated 18% of finished parts were held for re-inspection due to inconsistent first-pass results.

After a live demonstration, the customer installed the Optomech Opto QMM-900 — a non-contact, template-based inspection system with double telecentric optics, a 20 MP CMOS sensor, and ±5 µm measurement accuracy. The system measures up to 22 features per part in a single scan in under 8 seconds. All dimensional data is logged to an onboard SQL database and exported via LAN to the plant MES/ERP for live SPC trending. The Optomech applications team loaded 5 part templates in a structured two-day programming session. 340 active part programs are now in use — new programs are added in under 5 minutes.

"We used to have three experienced inspectors tied up full-time just on dimensional checks. Now one operator runs the QMM and handles three times the volume. The SPC data going into our MES has transformed how our production team responds to drift. We should have done this three years ago."
— Quality Manager, Precision Turned Components Manufacturer, Pune

A precision aerospace machining company in Bengaluru — a Tier 2 supplier to HAL, ISRO, and private aerospace integrators — produces complex profiled components including turbine shroud brackets, fuel system fittings, and aluminium structural sub-assemblies. These components carry stringent GD&T callouts: true position ±5 µm, profile tolerances of 0.008 mm, angularity to 10 arc-seconds, and full audit trails at every inspection stage. Their sole inspection method was a CMM housed in a dedicated air-conditioned lab requiring a 4-hour thermal soak per batch. A 25-feature component inspection took 35–45 minutes. With monthly throughput of 600–800 machined components, the CMM became a critical production constraint, often running 24 hours a day.

Optomech installed the VPP-CNC 4030 Video Profile Projector — a fully motorised CNC measuring system with 400 × 300 mm stage travel, telecentric zoom optics (0.7× to 4.5×), and a 3D touch probe for side-surface features. The unit was positioned on a vibration-isolation table adjacent to a 5-axis machining centre. The Optomech applications team programmed 10 CNC part programs in Learn Mode in four days — each measuring 18–32 GD&T features and generating a dimensioned PDF report with CAD overlay in under 9 minutes. AutoCAD DXF import aligns each program directly against the design drawing.

"We were completely dependent on our CMM lab. A single probe crash meant two days off the line. The VPP-CNC changed that entirely. It lives on the shop floor, the operators run it themselves, and the reports it produces are good enough for our NADCAP audit package. The Optomech team was excellent — they programmed 10 parts in four days."
— Quality Assurance Director, Precision Aerospace Machining Firm, Bengaluru

A mid-sized pharmaceutical packaging manufacturer in Hyderabad supplies glass vials, ampoules, aluminium closures, and rubber stoppers to formulation companies across India and regulated export markets (EU and US). Incoming quality acceptance required NABL-traceable dimensional inspection records. Inspection was performed with manual gauges across a 12-SKU range — slow (8–10 minutes per sample), highly operator-dependent, and generating no electronic records. Gauge R&R studies returned 31% — well above the 10% threshold required for gauge approval. Three batches were quarantined in a single quarter due to borderline dimensional non-conformances discovered only at the customer's goods-in inspection.

Optomech supplied the PP 300TE Optical Profile Projector with the OP1000 computerised metrology software — featuring full geometric element measurement, DXF overlay import, and XML/Excel export. Overlay charts — transparent Mylar templates engraved with nominal profiles and tolerance bands — were custom-fabricated by Optomech for all 12 SKUs, enabling pass/fail decisions in seconds. The system was calibrated against NABL-traceable master glass scales, and SOPs for all 12 product inspection routines were prepared jointly by the Optomech applications engineer and the customer's QA team.

"Our EU customer had flagged our gauge R&R as a major finding. We needed to resolve it before their next audit or risk losing the contract. The PP 300TE with the OP1000 system fixed it completely — 6.8% R&R, NABL traceability, electronic records, and overlay charts our operators can use in under three minutes. Optomech also helped us write the SOPs. We passed the follow-up audit with no observations."
— Head of Quality Assurance, Pharmaceutical Packaging Manufacturer, Hyderabad