Case study on machine vision enabled end of line inspection for Cutting Tools manufacturer
How Apex Vision helped achieve significant improvement in sampling frequency
The client, a manufacturer of cutting tools, sought to automate the measurement of coating delamination at the edge of their products. Traditional manual methods were time-consuming and prone to inconsistencies, hindering accurate defect detection and impacting product quality. Additionally, the client required statistically significant measurements for stringent process control and comprehensive data analysis to optimize their manufacturing processes.
Business Needs
- Measurement of coating delamination at the edge
- Statistically significant measurements for process control
- Data analysis for process control
Solution
- Developed a cutting-edge inspection system capable of delivering rapid measurements, completing each assessment in less than 5 seconds
- Utilizing specialized fixtures, our solution extended its capabilities to measure coating delamination on curved surfaces accurately.
- Implemented sophisticated data analysis techniques, including clustering by product type, to provide the client with actionable insights for enhanced process control and optimization.
Imapct
- Enabled a significant increase in sampling frequency, from 9 to 50 measurements per 4000 units. This enhanced sampling strategy provided a more comprehensive understanding of product quality, facilitating proactive defect detection and prevention.
- The client experienced a noticeable improvement in product quality by leveraging the insights gained from increased sampling and precise defect detection. This resulted in fewer defective units reaching customers, thereby enhancing customer satisfaction and brand reputation.
- The client's R&D team implemented modifications to their manufacturing process, successfully reducing the scrap rate from 5% to less than 1%.