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iQVision has a proven process to establish the scope of an inspection application, and create a clear functional specification to deliver against.
Potential solutions are tested and qualified, and then the optimal solution is implemented to ensure the inspection requirements are met reliably, every time.
This is iQVision’s 5-step implementation process:
UNDERSTAND – identify the product range and natural variations, assess production line conditions, understand the current process.
DEFINE – determine the quality criteria that need to be checked, ascertain how this can be automated using inspection systems. An experienced systems integrator is essential in defining achievable and workable criteria.
DESIGN – determine the hardware components needed to meet the application’s needs. It is important to understand the features and limitations of the various hardware options.
TRIAL – ensure that the solution is subject to rigorous conformance testing, and prove that the system will indeed perform in the nominated production environment.
IMPLEMENT – deliver a robust and reliable system that improves process control and meets expectations.
There’s no golden rule for implementing an inspection system. Every manufacturer’s needs, products and production lines are different. However, there are some essential things to remember if you want to get the best results:
Fit for the task: First and foremost, consider whether the inspection system fits your requirements. Does it include features that will pay back and give you the best possible return on investment (ROI)? For example, it’s always good to choose a checkweigher with a bit more up the sleeve in terms of belt speed and product memory. This will ensure it meets not only your business needs now, but in the future too. Work with your supplier to get the best solution for your unique needs.
Install the inspection machinery close to the end of the line. It goes without saying that inspection should be conducted as the very last process before the product leaves your premises. So wherever possible, install your inspection system at the end of the line (unless it is being used for a specific purpose such as sorting or equipment protection during the production process).
Know the rules for metal detection systems. Metal detectors are sensitive to metal, vibration, electrical noise, salt and moisture. So consider all these factors when implementing your system. The equipment supplier will be able to provide the best advice on whether this is the right solution for you, and how to install it effectively.
Take your time getting it right. The more time you spend getting the installation right upfront, the better the inspection system will work for your facility. Work with the supplier to ensure that you and your staff are trained properly and will get the most out of your system. (Find out how Matthews can help!)
Go for local service: As with every part of your automated production line, you need to ensure you can get support when you need it; does the supplier offer support that matches your requirements? Have they done similar systems before? A system that does not require special service tools or equipment is more cost-effective to run in the long term. And by choosing a supplier like Matthews that will be able to provide expertise and support on-site or remotely as required, you can ensure your systems are always running smoothly.
Live feedback: The ideal system will give operators live feedback when there is a problem – so that the problem can be corrected before it gets out of hand. This is often overlooked for vision in particular – but live feedback is critical if you are to get on top of problems before they get on top of you.
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