Center for Automation Technologies and Systems Success Stories

Handling and Inspecting Company: Bausch & Lomb (B&L), one of the oldest continually operating companies in the US, started in 1853 Contact Lenses in Rochester, New York as a small Challenge: Expanding Capacity While Improving Quality optical shop. The company has Bausch & Lomb manufactures contact lenses in its state-of-the-art facility in Rochester, NY, grown to become a multi-billion as well as at a number of other sites in the US and overseas. They approached Rensselaer dollar corporation, with approximately CATS to help optimize manufacturing, inspection and packaging processes for the Com- 13,000 employees worldwide and with pany’s new PureVision® line of contact lenses. B&L’s goals were to cost-effectively increase products available in more than 100 contact lens manufacturing capacity and improve quality control. B&L believed that they countries. Throughout its history, needed to automate the handling, inspection and packaging of contact lenses in order to B&L has developed innovative products, eliminate the inherent variability associated with manual processes and reduce costs. from rubber eyeglass frames, micro- scopes, binoculars and a light-sensing B&L sought external expertise in machine-vision-based inspection and industrial robotics camera shutter to ground-breaking that could expand their knowledge base and be dedicated to carrying the project forward. sunglasses for the military, the first They also wanted a ‘fresh set of eyes’ to analyze their challenges and develop novel solu- optical-quality glass made in America tions. Before B&L could contract with an automation systems integrator to build production and camera lenses used for the first systems, they needed to be able to clearly define any new processes, mitigate the associated satellite pictures of the moon. In 1971, risks by developing proof-of-concept prototypes, conduct process-reliability testing, and fully B&L introduced the first soft contact document process and system specifications. B&L also wanted help identifying a “best in lenses and is currently the largest class” automation systems integrator to implement their new processes in product automa- global provider of eye care products. tion systems. More information on B&L may be found at http://www.bausch.com/. “The CATS offered Bausch & Lomb experienced professionals with indus- try knowledge, a breadth of technology-focused contacts...and access to Industry: Bausch & Lomb offers a RPI and its resources...an opportunity that paid large dividends.” comprehensive portfolio of eye health Thomas F. Natalie – Engineering Manager, Bausch & Lomb products under one of the oldest, best known and most respected healthcare Alternatives. brands in the world. Its core businesses Bausch & Lomb considered continuing with existing manual processes involved in manu- include soft and rigid gas permeable facturing, inspecting and packaging PureVision® contact lenses, growing their workforce to contact lenses and lens care products, meet increased production demands. This approach was rejected, as it did not meet B&L’s ophthalmic surgical and pharmaceutical cost-savings or quality-control goals. Another option was to bring in consultants and/or products. vendors to help solve their manufacturing and process challenges; however, B&L concluded that such partners tend to have a somewhat limited solution set from which they draw upon Location: Rochester, New York (World to solve their clients’ needs. B&L wanted an unbiased look at their challenges, starting with Headquarters and World Optics Center) a clean sheet of paper. B&L could also have chosen to contract with an automation systems integrator to design and build new automated systems. But, systems integrators work best

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Rensselaer CATS is a NYSTAR-designated Center for Advanced Technology Center for Automation Technologies and Systems Success Stories

when they are first given detailed specifications with minimum levels of uncertainty – thus reducing costs, shortening schedules and minimizing technical risks. It was premature at this juncture for B&L to contract with an automation systems integrator.

A Systems Approach. Bausch & Lomb chose to partner with the Rensselaer Center for Automation Technologies and Systems (CATS) to benefit from an unbiased look at their contact lens manufacturing challenges. The robotics and machine vision expertise within the CATS were a good fit for B&L’s challenges and stated goals. The CATS worked closely with B&L engineers to fully understand the issues and research cost-effective solutions.

CATS researchers do not start projects with pre-conceived solutions in mind – they approach problems without bias and with a disciplined, systems methodology. A balance of modeling, analysis and experimentation, combined with creative design, was used to define B&L’s techni- cal problems and identify feasible solutions. An assessment was then jointly conducted with CATS and B&L personnel to identify high-risk aspects of the proposed solutions. For each area deemed to be high-risk, a laboratory concept prototype – or Proof of Principle Model (POPM) – was built in order to establish the viability of the proposed solution. These risk mitigation processes employed by CATS researchers have proved to be invaluable in reducing uncertainty and in achieving cost and schedule control. Portion of new Pure Vision ™ Contact lens Manufacturing line, employing CATS developed Once proposed solutions were proven in the laboratory, CATS researchers then worked with B&L processes. engineers to prepare detailed process specifications that would be used to contract produc- tion automation systems. In parallel, the CATS assisted B&L in conducting a best-in-class search and evaluation to identify the ‘right’ automation company for their production system design and build.

Results: Rensselaer CATS researchers succeeded in developing novel robotic material handling techniques for hydrated lenses, and solutions for machine-vision-based inspection of lenses prior to packaging. Process reliability tests demonstrated the soundness of the proposed solutions. Several US and international patents resulted from B&L’s partnership with the CATS (6,729,835 B2; 7,164,470; 7,079,239; WO 2005/038426; WO 2005/038424; WO 2003/082552). Progres- sive Machine and Design of Victor, New York was contracted to build multiple PureVision® contact lens manufacturing lines for B&L. These systems, employing processes developed by CATS researchers, were deployed in B&L’s facilities worldwide. Process reliability plot.

Center for Automation Technologies and Systems • Rensselaer Polytechnic Institute 110 8th Street – CII 8011, Troy, NY 12180-3590 (518) 276-8744 (voice) • (518) 276-4897 (fax) [email protected] • http://cats.rpi.edu/

Rensselaer CATS is a NYSTAR-designated Center for Advanced Technology