Case study on machine vision enabled process control for Sintered Products manufacturer
How Apex Vision reduced set up time by 67%
Our client, a sintered products manufacturer, was facing inefficiencies in the setup process for pressing green (good) products, leading to prolonged production lead times and reduced operational efficiency. Additionally, there were concerns regarding the accuracy of the manufacturing process, with deviations impacting product quality and consistency. Furthermore, the existing specifications lacked precision, resulting in variability in product performance and quality.
Addressing these challenges requires a comprehensive approach to streamline setup processes, enhance manufacturing accuracy, and refine specifications to ensure consistent product quality and meet stringent industry standards.
Business Needs
- Reducing setup time for pressing green products.
- Improving accuracy in the manufacturing process.
- Tightening specifications to meet stringent quality standards.
Solution
- Implemented a vision solution specifically designed for precise and efficient measurement of flash width during the setup of pressing green products.
- Utilized higher magnification images in the manufacturing process to achieve improved resolution and accuracy, by enhancing the level of detail captured during production.
- Integrated robust data recording capabilities into the manufacturing processi facilitating real-time monitoring and analysis of production metrics.
Imapct
- Achieved a remarkable reduction in setup time from 30 minutes to just 10 minutes.
- Tightened specification limits from 10 microns to 5 microns through the integration of higher magnification and enhanced measurement capabilities
- Reduced operator workload and reliance on human interpretation by automating image capture and measurement data collection processes resulting in minimizing potential errors
- Facilitated real-time monitoring and analysis by combining images with improved measurement data collection.