In 2006, Rite-Style Optical became the first independent lab in the country to “go digital” when it integrated its Lab Management System (LMS) with a Robotic High Production HSC Master and CCP Polishers it purchased from Schneider Optical Machines. Within a short period of time, the lab found it necessary to invest in more digital equipment due to increased demand, according to general manager Mike Sutton.

“The software systems we employ did not adversely change how we operate because of the advent of digital production,” Sutton recalled recently. “What did change was the coordination necessary between Rite-Style, the lens manufacturers, the equipment manufacturers and the LMS.” Sutton noted that the installation of a conveyance system was paramount to the efficiency of the robotic processing equipment.

Changes in inventory management became apparent only in the last year or so, Sutton said. “The amount of single vision blanks specific to free-form processing has certainly displaced the amount of conventional progressives that are inventoried,” he observed.

(L to R) Mike Sutton, George Lee and Ray Stavneak in the Rite-Style digital surfacing department.

Although the amount of labor needed to maintain the digital/robotic systems is considerably less than conventional processing, Sutton said increased demand has allowed Rite-Style to maintain its production staff without any layoffs due to the new technology. However, the qualifications that are necessary for employees have changed with the digital technology.

“Computer-savvy technicians with a mechanical background replaced machine operators who processed lenses,” Sutton pointed out. “Maintenance and calibration is paramount to successful free-form digital production,” he added.

Rite-Style uses digital surfacing to produce 85 percent of its lenses, according to Sutton. He defines digital lens surfacing as “any lens that is digitally surfaced either with two meridians of curves—atoric curves to enhance front PAL (progressive addition lens) designs or total backside, digitally surfaced free-form lens design.”

As digital surfacing took hold at Rite-Style, the company had to provide more training for its customer service reps. “One learning curve for the ECP is the understanding of ‘as worn’ technology and the relationship of fixed versus variable corridor, the ‘B’ measurement and add power,” Sutton noted.

Despite the large upfront investment required for digitally surfacing free-form lenses, Sutton said independent labs such as Rite-Style need to do it to remain competitive. “The ROI is in getting a greater profit margin on the free-form lenses,” he said, adding that the cost of the lenses decreases when factoring in less breakage and fewer remakes that result from digital’s greater accuracy. ■ ■