Bluewrist Insight

Zero Defect Manufacturing with Bluewrist

3D vision

Automated Vision Inspection for Zero Defect Manufacturing

In the world of modern 3D metrology, coordinate measuring machine (CMM) is a key investment for manufacturers to obtain 3D dimensional data in modeling and analytical applications. The vital needs to validate the dimensional and geometric accuracy and precision against GD&T profiles in the manufacturing and automotive industries cannot be understated. This is especially true as products are becoming increasingly complex and with a more litigious environment against defects, recalls and reputation damage, inspection solution must keep up and evolve with the changing environment using 3D vision automated inspection.

 

The adoption of CMMs is expected to grow in the foreseeable future with quality, accuracy and precision to be the topmost requirements for its end users. Inspection is crucial to certify the quality of parts and products, and also to guarantee a manufacturer’s compliance with industry standards. However, today’s inspection method that relies on CMM only measures limited samples of part’s geometry, and sampling is no longer sufficient to prevent downstream defects. Therefore, to achieve zero defect manufacturing, measurement and quality assurance must move away from the traditional measurement room, and to the production areas in order to achieve 100% inline inspection – where manufacturing conditions are continuously changing and hidden process errors could occur.

Automatic Quality Inspection in the Answer

In today’s modern production environment, 3D vision automated inspection workflow enables manufacturers to identify, analyze and fix issues in the manufacturing process before it leads to a downstream defect by harnessing the power of the digital twin. One should realize that it is no longer just a question of improving product quality, rather, it is to improve the entire production process. Unblink3D software solutions will better equip and prepare for success through preparation rather than reacting to problems as they emerge. In zero defect manufacturing nothing is left to chance.

Quality Data Should Not Exist in Isolation

A typical CMM allows probe movement along three axes that are orthogonal to each other in a 3D coordinate system. Traditionally, the dimensional data obtained from the CMM exist only in isolation and is backward looking – it does not provide real-time insight of the production process. Through the deployment of 100% inline automated 3D machine vision inspection solution, real time quality data of all parts generated from the inspection will be stored and analyzed by Unblink3D SPCWorks for predictive defect prevention. This allows potentially problematic areas to be intelligently and accurately identified to aid in rework and corrective actions. Armed with the ability to quickly detect component dimensional errors and surface defects, parts with bulges, dents, scratches or weld spatters could be avoided.

In addition to predictive defect prevention, the scanning and measurement performed in real-time at the production line will also ensure there will be minimal disruption to the production output, and guarantees problem-free final assembly – thereby enabling, with a high degree of confidence, the production of high-quality products via full traceability of all inspection data.

 

End users from various industry backgrounds consume our data differently to achieve their objectives. To illustrate the wide-ranging applicability of the automated 3D machine vision inspection and predictive defect prevention solutions, here are some examples of how the solution might be of assistance to different use cases. A plant manager might need plant-level reporting on downtime and total number of rejects. On the other hand, a line supervisor might want to look for model level rejects for line stoppage and overall model quality numbers. From the perspective of an operator, equipped with the knowledge observed from the automated inspection station could help assist them to make a quick decision on a rejected part – whether to contain and route to repair or continue build. Lastly, a QA/QC might utilize the data of the overall metrics on build quality, and proactively improve the process through the use of root cause analysis tools for continuous improvements.

Take Quality Control to the Next Level

A quality assurance weld inspector does traditional weld inspections. The weld inspector will perform an inspection on the weld joint to ensure it is up to standard. However, this inspection is very difficult to do on mass-produced goods, as well as costly for the manufacturer because it has to hire an additional individual or a team of individuals to complete the job.

 

Quality assurance weld inspectors use different methods for inspecting the weld, including visually inspecting the weld, and a variety of tools, including magnifying glasses, flashlights, handheld gauges, tape measures, and calipers. The tools to be used by the weld inspector depends on the weld in question and the type of defect. These tests are only as reliable as the workers performing them. If the worker fails to complete a test or completed a test improperly, the reliability of the weld can be called into question, causing a big headache for the company. Weld inspection is often a tedious process that calls for a keen eye for detail and patience; inspectors can be responsible for inspecting hundreds to thousands of welds per shift.

 

Individual inspection is subjective to each inspector, making it very hard for manufacturers to ensure that each defect is caught. With an automated inspection solution, defect detection is based on measurements and mathematical formulas, ensuring that all defects that fit a certain set of criteria are caught before they can be passed downstream in the production line.

 

New methods have been developed that make weld inspection much easier for manufacturers who produce large numbers of products. Bluewrist Inc. offers a 100% in-line weld inspection solution. This solution uses a 3D profiler or 3D snapshot sensor to capture detailed surface characteristics of the weld. The weld can be inspected fully or broken down into individual sections for analysis and comparison against fabrication blueprints to guarantee the weld conforms to the specifications.

Conclusion – Don’t Leave Weld Inspection to Chance and Subjectivity

As we have seen in today’s manufacturing landscape, it is more important than ever to have strong, quality welds. The public demands higher quality goods, and welds are often of critical importance in the structure of a product. The reliability of a weld can play a huge factor in the success or failure of any company that procures welded products and in the public’s perception of the quality of that brand as a whole. Zero Defect Manufacturing is here to solve the problem.

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