Repeatability and Reproducibility Method of Hand-handle Laser Triangulation Profilometer

This paper explores the use of a hand-held laser triangulation-based measurement system for gap and flush measurements in the automotive industry, focusing on operator variability. In modern manufacturing, especially with Industry 5.0, precise measurements are essential for quality and efficiency. While laser triangulation technology offers high accuracy, when the device is portable human factors influence performance. The study evaluates the U-Sense.IT srl G3F laser profilometer in two modes: manual and with a magnetic holder. Using Measurement System Analysis (MSA), the research assesses repeatability (Equipment Variation, EV) and reproducibility (Appraiser Variation, AV), determining the Gauge Repeatability and Reproducibility (GRR). Data were collected from three operators measuring three cars, with repeated measurements for both gap and flush. Results show that the holder technique has lower variability in both repeatability and reproducibility compared to the manual method. The GRR for the holder was 2,22% for flush and 2,32% for gap, while the manual technique showed 3,13% for flush and 3,66% for gap. Both systems had GRR values below the acceptable 10% threshold, with the magnetic holder system demonstrating greater precision due to better sensor positioning. This research highlights the effectiveness of support systems in reducing human error, even if it reduces flexibility, showing that while both methods are valid, the magnetic holder system aligns better with Industry 5.0 principles by improving collaboration between humans and intelligent systems.