Pinnacle Optical in Birmingham, AL is dedicated to “the best quality, best service, and best vision”. Though they are a relatively small lab, Pinnacle utilizes cutting-edge, industry-leading technology in their facility, ensuring pristine optics. Their staff of dedicated employees understands doctors’ and opticians’ need for high quality ophthalmic lenses delivered with a sense of urgency, yet they are always conscious that attention to detail is not neglected. Greg Blackwell, Managing Partner, is committed to the company’s vision for best quality, best service and best vision. It is with this commitment that Greg recognized the need to look to the future to enhance their production. Their goal - to increase production and reduce breakage while utilizing the same floor space.

Running out of space
The optical lens manufacturing industry is undergoing dynamic changes. Many companies are embracing material handling automation and are, therefore, growing. Other companies, that are resisting, are beginning to lose their competitive edge. Many small companies feel that they cannot afford to automate. Others, like Pinnacle Optical, knew that they could not afford to ignore automation.

Their facility occupies space on the third floor of a medical office building and moving or increasing the size of their facility were not options. They tried a competitor’s solution, but it never came close to meeting promised efficiency gains or expectations.

Maximum throughput
FlexLink’s Optical Team created a unique solution for Pinnacle by combining experience from FlexLink’s 25+ year history and it’s 100+ optical lab installations.

The solution included additional accumulation areas, overhead conveyors to increase available floor space, an industry-leading tray destacker, a lift gate to provide walk-through access, and even a special puck to handle a bowl that carries “tools” back to the beginning of the line. The resulting system provided maximum throughput with limited floor space while decreasing operator handling, thus decreasing breakage. 

After just one week, Blackwell reported that production increased 20% while his scrap rate dropped from 2.9% to 1.5%! Now, there are less people - and only the right people - handling the product.

In fact, though they were used to working 9 - 10 hour days, soon after the system was up & running, they completed all their jobs in less than 8 hours - so they went home!

Blackwell has discovered another, unforeseen benefit to partnering with FlexLink. Working with Pinnacle Optical’s Sales and Marketing Managers, Shelley Hiett and Jeffrey Crooks, he has instituted an “open house” option for all new and existing accounts. When prospective clients visit his new, state-of-the-art manufacturing facility, they know that they are now working with a very progressive supplier. Can a conveyor system really be a sales tool? “Selling” Pinnacle Optical’s capabilities is now much easier! 

The hard facts 

• Opened lab in November 2002.
• Increased jpd by 20% immediately (up to 225).
• Reduced scrap rate from 2.9% to 1.5%.
• Saved labor hours by reducing shifts from 9 to 10 hours to standard 8 hour day.
• Installation crew and process had no negative effect on existing production.
• FlexLink’s automation reduced handling and breakage, and increased work place safety by eliminating current vertical stacking. 
• System allows Pinnacle to double production capacity without buying any new equipment.