IVS Installs 15 Camera Quality Control Vision Machine at Prestigious Automotive Customer

IVS install 15 camera vision machine to prestigious automotive customer for the inspection of a key part of the main drive chain. The front corner braking assembly quality control system is integrated as a final inspection of the complete unit prior to release to the main production line. The fully integrated machine vision system provides 100% inspection of the full sub-assembly.

15 camera vision machine
Front corner sub asssembly vision system
Vision camera inspection

Major safety accreditation for Industrial Vision Systems ltd

Industrial Vision Systems Ltd are pleased to announce their accreditation by Safecontractor®. Safecontractor is a leading third party scheme which recognises very high standards in health and safety management amongst contractors and suppliers. The company’s application for Safecontractor accreditation was driven by the need for a uniform standard across the business and will enhance the ability of IVS to attract new contracts and clients.

safecontractor logo for industrial vision systemsSafecontractor is applicable to most sectors although it is particularly relevant to automotive, pharmaceutical and food manufacture, all of which are big users of contracted services. John Kinge, technical director of Safecontractor said, “Major organisations simply cannot afford to run the risk of employing contractors who are not able to prove that they have sound health and safety policies in place.”

“More companies need to understand the importance of adopting good risk management in the way that Industrial Vision Systems has done. The firm’s high standard has set an example which hopefully will be followed by other companies within the machine vision sector. Safecontractor plays a vital role in supporting our clients in meeting their compliance needs, whilst working with their contractors as they progress through the accreditation process.”

Under the Safecontractor scheme, Industrial Vision Systems underwent a vetting process which examined health and safety procedures and their track record for safe practice. Only companies meeting the high standard are included on a database, which is accessible to registered users only via a website. Client-organisations who sign up to the scheme can access the database, enabling them to vet potential contractors before they even set foot on site. Hundreds of major, nation-wide businesses, from several key sectors, have signed up to use the scheme when selecting contractors for services such as mechanical, electrical, building and machine building work.

Unique Device Identifier (UDI) inspection update

Device makers look to on-line vision systems to quality check the FDA’s unique device identifier requirements.

The Food and Drug Administration (FDA) in the US have released a final ruling requiring that most medical devices distributed in the United States must carry a unique device identifier (UDI). With the directive starting in September 2014 it has become increasingly important for device manufacturers to put the necessary quality control procedures in place now to confirm the UDI is both legible and traceable. As the FDA sees it, “A unique device identifier system has the potential to improve the quality of information in medical device adverse event reports, which will help the FDA identify product problems more quickly, better target recalls, and improve patient safety.” The UDI allows the device or product to be traced back to its roots in manufacturing.

Unique device identifier vision system

This directive has implications for the whole of the medical device and pharmaceutical business but at a fundamental level during the production of the device or product the UDI needs to be applied and quality checked to confirm it meets the necessary specification.

Industrial Vision Systems (IVS) have been working with a number of companies to tackle these problems through the use of ever more sophisticated automated machine vision systems and processes. The FDA demands that automatic identification and data capture (AIDC) technology is used for the inspection process. By combining Optical Character Recognition/Optical Character Verification with print quality inspection and ID/code reading the UDI can be checked in real time through the whole production cycle to confirm compliance to the FDA specifications. The UDI can be applied to labels, boxes, products, components and devices – therefore a generic approach to the quality inspection needs to constructed. The UDI directive also states that all devices that will be implanted or sterilised must have permanent marks so the vision inspection system has to cope with confirming marks on varying material types, including implants.

Typically the code would be applied to include both a human readable and a machine readable mark, be it a 1D or 2D/Data Matrix code. Both need to be inspected to confirm they reach the necessary quality standards. For symbols this is according to the ISO standards 15415 and 15416. Digital cameras are used throughout the production process connected to a central IVS vision system which then communicates to the Factory Information System database to provide historical information and conformance. Full track and trace is now seen as the ideal solution. Most medical device companies run varied quality systems, data management and IT applications for their UDI requirements. The flexible user interface allows data storage, image storage and historical statistical process control (SPC) data to be easily managed independent of the background IT infrastructure.

These latest generation vision systems provide full audit logging and traceability to allow systems to be validated to Good Automated Manufacturing Practice (GAMP) standards. The UDI quality can be tracked through the process to make sure that it has not degraded through the production cycle and that multiple elements (e.g. inserts and instructions) have gone together correctly.

The UDI program will provide consumers with a better quality product, increased traceability against forgery and assurance that the product has been through the necessary production cycle and checks.

Further details can be found on the FDA website www.fda.gov/udi and information on quality checking the UDI can be found at www.industrialvision.co.uk/industries/medical-devices-pharmaceuticals

Vision system machine inspects automotive components

June 2014. IVS have built a new machine for a major Tier 1 manufacturer of automotive components.

The build of an automotive handle comprises of many differing production processes including pressure die casting, injection moulding, painting and assembly of the final unit. All of these processes require careful planning to achieve the quality levels expected of a Tier 1 automotive supplier. The final inspection of the assembled unit and kit of handles which make up a complete car is critical prior to the product leaving the factory.

Automated vision inspection machine

Because of this, the large UK-based OEM manufacturer of automotive door handles approached IVS to automate the process for inspection of these parts. The manufacturer produces an average of 100,000 keys or ID-devices, 60,000 door handles and 24,000 steering column locks each day and the quality of the products manufactured is critical to their success.

The manufacturer required a machine to perform a number of inspection tasks as part of the final automatic quality control of the product.

The complete case study can be found here.

A video of the machine in action can be found on our YouTube channel.

New High Speed Machine Vision Cameras

Industrial Vision Systems (IVS) are pleased to announce the new line-up of digital vision system cameras offering even greater speeds of inspection, coupled with higher resolution. The latest NCHG220 color camera offers a resolution of 2048 x 1088 at 105 frames per second, offering the ability to inspect up to 6,300 parts per minute on a single camera – one of the fastest vision systems available on the market today.

IVS vision camera systems can be configured and deployed with ease thanks to plug and play support within the industry standard NeuroCheck® software suite. These latest generation machine vision cameras provide state-of-the-art digital technology, offering precise signal processing and superior image quality.

The IVS suite of factory communication solutions ensures that IVS vision systems can connect and communicate with a diverse range of factory floor PLC and control devices. The new cameras can be configured for hundreds of different applications covering presence verification, measurement, guidance and identification.

New IVS Vision System Cameras Datasheet

Vision System Automatically Checks Aerospace Assembly

A new video on the IndustrialVision YouTube channel showcases a special purpose vision machine for the inspection of a complex aerospace sub-assembly. Quality and reliability are essential, and so automated visual inspection is crucial to the manufacturing process. This machine was designed as a final end of line inspection machine to confirm product quality before it is shipped to the customer.

IVS created a special purpose inspection machine utilising five digital Gigabit Ethernet cameras and one pan, tilt and zoom camera. Lighting is an integral part of the system, using high intensity white LEDs combined with red laser line projections. IVS machine vision software contains a wide range of standard inspection functions, making it applicable to any industry. The software determines that the complete sub-assembly is manufactured correctly looking for machined surfaces, inserts, labels, screws and helicoills.

The aerospace customer can be assured that what they are supplying to their customer is of the highest quality and reliability. In addition they have historical photos and data supplied from the machine for every product leaving their factory for future traceability.

The video can be viewed at: http://youtu.be/9RGBTXR-h6A

Automation Fuels US Automotive Manufacturers Resurgence

Vision systems continue to be a key aspect of industrial automation and allow manufacturers to increase yield and quality across their factories. According to “AutomationWorld” automation and flexible manufacturing techniques are supporting U.S. automotive manufacturers ability to meet the increasing demand. Machine vision systems are critical requirements when it comes to adopting flexible and lean manufacturing techniques.

According to the article “flexible manufacturing is the current mantra for U.S. automakers. In 2008, automotive plants closed, unions restructured contracts, and Tier 1 and 2 suppliers simply went out of business due to lack of sales. In 2009, U.S. vehicle sales plummeted to 10.4 million units, and 27 U.S.-based auto plants were closed.

Fast forward to 2013 and U.S. automotive plants are running three shifts, six days a week, and edmunds.com predicts more than 15.5 million U.S. vehicles will be sold, with forecasts of 16.4 million units to be sold in 2014. Chrysler sales alone hit a six-year high in 2013.

Chrysler has three less assembly plants than they did 5 years ago and one less stamping plant therefore this can only be achieved through greater use of automation.”