Industrial vision quality control offers significant advantages: precise defect detection, increased productivity, and overall improvement in product quality. However, this type of project requires rigorous planning and methodical execution to ensure its success.
Here are the main steps to successfully carry out a industrial vision projectfrom the definition of needs to post-installation support. We will also address crucial concepts such as the failure library, the importance of the feasibility study, and user training.
STEP 1: SPECIFICATIONS
The specifications document is the cornerstone of any successful project. This initial step aims to clearly define the project's objectives and constraints in order to guide technical and strategic choices.
KEY ELEMENTS TO INCLUDE IN THE SPECIFICATIONS
- The objectives of quality control: What defects or anomalies need to be detected? What level of precision is required? How is the control currently performed? What are the different impacts of this control on production?
- Production rate: Should the system integrate into a high-speed line or into a slower but more complex process? Should the control be done on 100% of the products or only through sampling?
- The types of defects to address: Are they scratches, deformations, dimensional discrepancies, or other irregularities? Are they aesthetic defects or functional ones?
THE IMPORTANCE OF DEFECT LIBRARY
A defect library is a collection of images and/or parts representing compliant and defective products. It plays a crucial role from this phase:
- It helps to illustrate the typical defects for providers or technical teams.
- It serves as a working basis for developing algorithms or training artificial intelligence models.
- It forms the basis for the future validation of the automated quality control system. It prevents any disputes during final delivery.
CODA Systèmes supports its clients in this stage by helping to structure their needs and by identifying the specific constraints of each production environment.
STEP 2: FEASIBILITY STAGE
The feasibility study validates that the project is technically achievable and economically viable. It is an essential step to avoid costly mistakes downstream.
What the feasibility study must include
- Equipment tests: Identify the cameras, optics, and lighting suitable for the specific characteristics of the rooms and the production environment.
- Validation of AI algorithms or models: Traditional or AI-based vision software must be tested with the defect library to verify their ability to detect the expected defects.
- Analysis of environmental constraints: Assess the variations in lighting, temperature, or speed of parts on the line. Part of the study can also be conducted directly on the production line to anticipate these environmental issues.
A well-conducted study also allows for the comparison of different configurations to choose the most efficient solution at the best cost. At CODA Systems, we have a comprehensive methodology that enables us to offer a results commitment.
STEP 3: SOLUTION DEVELOPMENT
Once the feasibility is validated, the development phase can begin. It involves designing a technical solution that meets the objectives defined in the specifications.
THE KEY ELEMENTS OF DEVELOPMENT
- Equipment selection: High-resolution cameras, lenses, optimized lighting, sensors, or industrial programmable controllers for integration into the process.
- Algorithm programming: This can include traditional algorithms (edge detection, pattern recognition) or models based on deep learning.
- User interface creation: of crucial importance, it must be intuitive to facilitate its adoption by the teams.
At CODA Systems, this step is carried out by engineers specialized in industrial vision, ensuring complete customization of the programs to meet the client's specific needs.
STEP 4: INTEGRATION AND COMMISSIONING
Integration involves installing the system in the production environment and connecting it to existing equipment (production line, controllers, MES systems).
THE CRITICAL POINTS OF INTEGRATION
- System calibration: to ensure that the cameras and optics are correctly positioned to cover the entire rooms.
- Real-world testing: Simulate production to identify necessary adjustments before the official commissioning.
- Mechanical integration and automation: This step may include the development of custom mechanical structures and the integration of automated modules.
With its expertise in mechanical engineering and automation, CODA Systems ensures a smooth and efficient integration.
STEP 5: USER TRAINING
An efficient system will only be effective if operators, technicians and quality managers know how to use it correctly. Training is therefore a crucial investment to ensure long-term success.
TRAINING OBJECTIVES
- Learn to use the system: Set up inspections, analyze results, and diagnose defects.
- Ensure first-level maintenance: Change settings or resolve minor issues without fully relying on technical support.
- Developing team autonomy: A trained team is more responsive to production variations or technological changes.
CODA Systems offers custom trainings adapted to the specific needs of each client, covering both hardware and software aspects. Its training organization CODA Formations, certified QUALIOPI, offers a large number of training modules provided by field experts with vision.
STEP 6: TECHNICAL SUPPORT AND MAINTENANCE
After commissioning, an industrial vision system requires monitoring to ensure its performance over time.
ESSENTIAL SERVICES AFTER INSTALLATION
- Responsive technical support: To quickly resolve issues and minimize production downtime.
- Software updates: Integration of new features or performance optimization.
- Preventive maintenance: Periodic inspection of equipment to avoid breakdowns.
With tailored maintenance contracts, CODA Systèmes provides sustainable support for its clients.
CONCLUSION: HOW TO SUCCEED IN YOUR QUALITY CONTROL PROJECT THROUGH INDUSTRIAL VISION?
A quality control project using industrial vision is a structured process that relies on specific steps:
- Creation of a complete specifications document, including the defect library.
- Conducting a thorough feasibility study.
- Development of a suitable technical solution.
- Integration and commissioning in production.
- In-depth user training.
- Post-installation follow-up with technical support and maintenance.
By following this methodology, you maximize your chances of success and fully leverage your investment. With its expertise and turnkey solutions, CODA Systems can support you at every step to ensure a smooth implementation and optimal performance.