Quality Control Vision System

The system using vision sensors and analytical software automates the quality control process, reducing the need for manual work and eliminating human errors. Automation ensures higher product quality, increases production efficiency and reduces operating costs.

A plastic products factory commissioned us to design and implement a quality control vision system. The project aimed to increase production efficiency and improve product quality.

Quality Problems

The factory faced several serious problems regarding the quality of its products:

Surface irregularities and defects: The occurrence of cracks, holes and other surface defects that were difficult to detect by manual inspection.
Incorrect dimensions: Variations in product dimensions that often led to non-compliance with customer requirements.
Low inspection efficiency: Detailed manual quality control was time-consuming and prone to human error, leading to low productivity and inefficiencies in production.

Research and Development Part

The research and development process that led to the development of our solution included several key stages:

  • Requirements Analysis: We conducted a detailed analysis of quality problems in the factory and customer requirements. We have identified the most common defects and those that cause the most trouble for manual testers. We defined the parameters that the system had to monitor.
  • Market Research: We analyzed available vision technologies, selecting vision sensors with high accuracy, speed of operation and ease of integration with the customer’s vision software and hardware.
  • Prototyping: We developed a prototype of the vision system, which was tested on the factory production line. These tests allowed us to introduce the necessary modifications and optimizations.
  • Integration and Tests: After the prototype was approved, the system was integrated into the full production line. We performed extensive testing to ensure the system functions properly in real production conditions.
  • Staff Training: We trained factory staff in the operation and maintenance of the new system, providing technical support at every stage of implementation.

Elements and Technologies Used

  1. Vision sensors: The basic element of the system, responsible for capturing and analyzing images of plastic products.
  2. LED illumination: Provides even and adequate illumination for vision sensors, which is crucial for precise analysis.
  3. Industrial computer: Controls the entire system, analyzes data from sensors and makes decisions about product quality. We used a device of our own production for this purpose.
  4. Analytical software: Uses advanced algorithms to detect defects and deviations from the norm. We used a ready-made solution due to the complexity of the algorithms analyzing the sent image. The user interface allows operators to easily configure the system, monitor the quality control process, and view results.

Long-term profit for the customer

Improved product quality: Using a vision system, the factory can ensure that each product meets high-quality standards, which increases customer satisfaction and minimizes complaints.
Increased efficiency: Automating quality control allows for faster product processing, which increases the overall efficiency of production lines.
Cost reduction: Fewer rejections and reduced manual inspections.

The implementation of the quality control vision system brought tangible benefits to the factory. Automation of the quality control process ensures higher product quality, increases production efficiency and reduces operating costs. Thanks to this, our client can meet market requirements and remain competitive.

We are proud of this project and recommend vision systems as an effective tool for quality control in various manufacturing industries.

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