Document Product Quality and Eliminate Disputes with Machine Vision

“I caught a record-breaking walleye last weekend,” an excited Joe announced to his colleagues after returning from his annual fishing excursion to Canada.

“Record-breaking?  Really?  Prove it.” demanded his doubtful co-worker.

Well, I left my cell phone in the cabin so it wouldn’t get wet on the boat so I couldn’t take a picture, but I swear that big guy was the main course for dinner.”

“Okay, sure it was Joe.”

We have all been there — spotted a mountain lion, witnessed an amazing random human interaction, or maybe caught a glimpse at a shooting star.  These are great stories, but they are so much more believable and memorable with a picture or video to back them up.  Now a days, we all carry a camera within arm’s reach.  Capturing life events has never been easier and more common, so why not use cameras to document and record important events and stages within your manufacturing process?

As the smart phone becomes more advanced and common, so does the technology and hardware for industrial cameras (i.e. machine vision).  Machine vision can do so much more than pass fail and measurement type applications.  Taking, storing, and relaying pictures along different stages of a production process could not only set you apart from the competition but also save you costly quality disputes after it leaves your facility.  A picture can tell a thousand words, so what do you want to tell the world?  Here are just a couple examples how you can back up you brand with machine vision:

Package integrity: We have all seen the reduced rack at a grocery store where a can is dented or missing a label.  If this was caused by a large-scale label application defect, someone is losing business.  So, before everyone starts pointing fingers, the manufacturer could simply provide a saved image from their end-of line-vision system to prove the cans were labeled when shipped from their facility.

Assembly defects: When you are producing assembled parts for a larger manufacturer, the standards they set are what you live and die by.  If there is ever a dispute, having several saved images from either individual parts or an audit of them throughout the day could prove your final product met their specifications and could save your contract.

Barcode legibility and placement: Show your retail partners that your product’s bar code will not frustrate the cashier by having to overcome a poorly printed or placed barcode.  Share images with them to show an industrial camera easily reading the code along the packaging line ensuring a hassle-free checkout as well as a barcode grade to ensure their barcode requirements are being met.

In closing, pictures always help tell a story and make it more credible.  Ideally your customers will take your word for it, but when you catch the record-breaking walleye, you want to prove it.

Eliminating Manufacturing Errors Begins with Identifying Trouble Spots

We have all gotten that dreaded phone call or email…the customer received their order, but there was a significant problem:

  • ErrorProofingTagsMissing part
  • Wrong color
  • Leaking seal
  • Improper assembly
  • Too lose…or too tight
  • Incomplete processing, e.g. missing threads
  • Something is damaged
  • Missing fluids or fluids at wrong level
  • …and so on

Assuming that we have reliable suppliers delivering quality parts that meet the required specifications…everything else that can (and often does) go wrong happens inside our own facilities. That means that solving the issues is our responsibility, but it also means that the solutions are completely under our control.

During the initial quality response meetings, at some point the subjects of “better worker training” and “more attention to detail and self-inspection” may come up. They are valid subjects that need to be addressed, but let’s face it: not every manufacturing and assembly problem can be solved by increased worker vigilance and dedication to workmanship. Nor, for that matter, is there the luxury of time or capacity for each worker to spend the extra time needed to ensure zero defects through inspection.

It is often more effective to eliminate errors at their source before they occur, so that further human intervention isn’t required or expected.

Some things to look for when searching for manufacturing trouble spots:

  • Are all fasteners present and properly tightened, in the proper torque sequence
  • Correct machine setup: is the right tool or fixture in place for the product being produced?
  • Manual data entry: does the process rely on human accuracy to input machine or product data?
  • Incorrect part: is it simply too hard to determine small differences by visual means alone?
  • Sequencing error: were the parts correct but came together in the wrong sequence?
  • Mislabeled component: would the operator realize that part is wrong if it was labeled incorrectly in the first place? Sometimes where the error has impact and where it actually occurred are in two different places.
  • Part not seated correctly: is everything is correct, but sometimes the part doesn’t sit properly in the assembly fixture?
  • Critical fluids: is the right fluid installed? Is it filled to the proper level?

Once the trouble spots have been identified, the next step is to implement a detection and/or prevention strategy. More information on the error proofing process is available on the Balluff website at www.balluff.us/errorproofing