#manufacuring defects detection

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How does an Intelligent Machine Vision System Help Combat Quality Loss While Manufacturing?

Every aspect of manufacturing centers producing the best quality products. The production process comprises multiple steps and each step needs to be monitored carefully. Traditionally, manufacturers needed to assign quality inspections to multiple people hence, making it a labor-intensive task. However, manufacturers are now switching to technology for quality inspection. There are certain machine vision systems available like Trident’s Vision Intelligence System that offer automatic quality inspection during production while enabling manufacturers to discard defective pieces right away.

Switching to automation is the first step towards revolution; traditional quality inspection would come up with various drawbacks such as:  

Some defects might slip from the human eye if production is massive.  

Sometimes it gets tough to differentiate between slightly assorted color spectrums.  

Separate locations need different employees to inspect quality, hence making it a labor-intensive task.  

Traditional labor is prone to errors, subjectivity, and burnouts.  

It is a bit harder to scale up manual quality inspections than automatic ones.  

Conventional machines might not detect unanticipated errors.  

In contrast to the traditional quality inspection, where the machine works according to the programming embedded within, an AI-based inspection is different. It follows a self-learning algorithm that can distinguish anomalies from defects. They can easily modify themselves to inspect productions with added complexities or changed floor plans. AI is basically a technology that can be as flexible as a human inspection followed by extra speed and reliability.  

Analysis Data from Distinct Sources

Artificial Intelligence-based technology can be trained with multiple touchpoints so it could acknowledge deviations between defects and accepted variations. It can also capture new data points in order to gain high identification rates. You can eat in defect detection as-well-as parts positioning. It is capable of self-learning and classification of data for providing more accurate inspection results.

Automates Data Capturing and Reporting  

AI-based machine vision systems can extract relevant information from massive datasets and minimal initial parameters for data processing. It can modify data to improve maintenance and inspection algorithmic rules. They can accumulate massive structure and unstructured data, then classify and tag it then. The metadata received provides essential insights into the manufacturing equipment enabling companies to for repair, maintenance, and replacement decisions. They can generate comprehensive defect reports and graphs on pixel-level nuances.

Why does Your Manufacturing Business Need This Technology?

Where human inspection is best for qualitative interpretation of complicated and distorted scenes, machine vision systems are best for quantitative measures of structured scenes. Credited to its speed, accuracy, and reliability, it can inspect thousands of parts in a minute. This system comes with various other benefits to your business such as:  

Combats Labor Shortage  

During the current times: where labor shortage is among the topmost crises, a machine vision system can help combat this issue. The machine is more reliable, accurate, quick, needs no human labor, and can deal perfectly with a labor shortage. The manufacturer can optimally utilize its workforce into different sections where human efforts can do a better job.  

Cuts Cost

Assigning one vision system is more cost-effective than multiple people to the same work. Machines alone can detect defects in minutes more effectively. As soon as a defect is caught, an alert flash on the system screen monitored by the inspector. If human inspection is in place, the time consumed to report the relevant person can cost the manufacturer production quality.  

Higher Accuracy

This AI-based system promises greater accuracy and reliability as it can detect defects more accurately. Having high-quality cameras in place can easily capture minute scratches on the automobile parts that human eyes might pass. It can even defect small insects or even dust particles while FMCG products are produced.  

Boosted Quality  

Having a system that can accurately detect even the minute defects, guarantees a lesser scope of defective pieces to pass through the conveyor belt. Programmed to follow a specific quality standard and variation acceptability, the system can even identify the variation in the spectrum of the product. If the cement color is much darker than grey, it can recognize the issue right away and notify the concerned person.  

Flexibility and Scalability

AI-based systems are designed to be flexible enough to identify the variation even on different floor spaces. It can accumulate data from distinct datasets while turning it into a comprehensive report. These reports are necessary to make small and huge decisions on manufacturing. Businesses can scale with the right judgments.  

Reduced Floor Space  

One machine vision system against multiple labors reduces floor space and complies with social distancing. Having floor space freed causes less or no fuss around. Employees can be assigned different tasks while optimizing their potential. Employees can roam in the area more freely without bumping into one another.  

Trident offers an AI-based Vision Intelligence System, that has a record of accomplishment of benefitting various manufacturing businesses. The manufacturer can implement this innovation for FMCG, automotive, glass, laminates, pharmaceuticals, and PPE detection. Being handled by a team of experts, the inspection process is continuous and can be modified as per the client’s requirements. Contact us for further information.

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Reshape Your Quality Process with Vision Intelligence System

Since the manufacturing sector in the Indian economy counts about 17% at current, it indeed is prominent. However, Manufacturers, these days are mounted with tremendous pressure to provide quality as well as speedy production. If done in silos, it can be time-consuming, especially the quality check part, which demands more labor as compared to a Vision Intelligence System.  

Quality control is what many manufacturers struggle with. The traditional belief of quality check as a labor-intensive task blocks the countless opportunities crossing their paths. These days, one of the key issues contributing to the issue is a labor shortage. This pandemic has driven the gap to the next level, mounting existing employees with additions to the scope of their jobs assigned.   

Other than this, traditional quality inspections might come up with issues like: 

Monitoring different     parts and materials makes it harder to handle quality control for     complicated products 

Inability to identify     the distinct spectrum of colors.  

Human eyes might miss     minute errors like small scratches, dust particles, and so on.  

Lack of resources and     time might compromise product quality. 

What is a Vision Intelligence System, and How Does it Work? 

Vision Intelligence System is a product designed by Trident Information Systems specifically for manufacturers. It automatically detects product defects like scratches, dust particles, broken pieces, etc. straight from the conveyor belt with least or no human interference. But how does it work? 

Our computer vision     engineers first understand the issue/customer requirements.  

Then they collect data     in the form of images, followed by developing algorithms and     models.  

They then test the     hypothesis / validate the models.  

After testing     and finalizing every step they either offer POC (Proof of     Concept) or proceed for onsite implementation (according to the     customer’s requirement). 

Trident’s Vision Intelligence System Covers seven industries, i.e., automotive, retail and FMCG, packaging and printing, pharmaceutical, glass, laminate, and cement.  

Automotive Industry: Automotive manufacturers can classify different product variants based on color, shape, design, size, and so on. It also detects visual defects like a dent, scratch, burr, chip, etc. Vision Intelligence System can read barcode labels and 2D barcodes directly from the marked parts, verify labels as well as direct part marks. Additionally, they can detect wrinkles, dents, cracks, and piston defects.  

Retail and FMCG Industry: With the help of this technology, you can check the structural quality, operational quality, and dimensional accuracy within seconds. You can assure accurate ingredients and standard quality. You may also detect foreign particles like dust, stones, insects, little animals, and so on.  

Printing and Packaging Industry: With VIS, you can spot packaging defects such as improper passing, irregular packing, torn parts, and so on in FMCG products. Enable high-speed detection straight on conveyors, spot missing components, read QR codes and barcodes, classify products, and a lot more with optical and thermal camera vision.  

Glass Industry: Being one of the most brittle materials, glass needs extra care. Identify inaccurate logos, scratches, breakages, cracks, air bubbles, etc. Ensure all the parts are glued properly and check if the logo has been printed as it should be with VIS.  

Laminate Industry: You no longer have to deal with the risk of dispatching defective sheets. Ensure accurate chemical composition during the mixing process. Identify laminate placements, pick-up operations, machine alerts. VIS also helps identify raisin spots, dust, design defects, and mosquito defects.  

Pharmaceutical Industry: Manufacturers of medical devices, bioscience products, and pharmaceuticals need cost-efficient technology to check the quality. You can control the packaging quality, check fusion bottles, and track your products more precisely with the Visual Inspection in Manufacturing.  

Vision Intelligence System for Employee Safety 

Vision Intelligence System for Employee Safety ensures safety of your employees. It has two segments dedicated to the section, i.e., Face Mask Detection and Safety Gadget Inspection. In both cases, the system spots employees not adhering to safety standards.  

The Face Mask detection solution (FMD) comprises two main branches:  

Mask Detection – which detects     employees wearing masks.  

Face Detection – The system     recognizes faces not having masks on and maps his face followed by the     employee’s details in the database.  

The employer can also conduct contactless attendance: when a person comes to the institute, wait for a little while and let the camera capture their image. This solution then recognizes the employee’s face and marks his attendance. It considers the first entry as the arrival time and the last entry as the departure.  

The other one is Safety Gadget Inspection, where the system identifies if the employee carries safety equipment that has been allotted to him. It detects partial compliance as well such as – no helmet, employees without a harness, and so on.  

Manual Inspection is bound to limitations. It is a lot more labor-intensive as well as time-consuming as compared to automatic defect detection. Trident Information Systems offers a robust Vision Intelligence System reinforcing manufacturers with automatic technology detecting defects more precisely while demanding least or no human interaction. Thus, filling the labor shortage without burdening existing employees.��Contact us for further information or a demo.