Vision Sensor Technology Increases Production Reliability
In the product manufacturing process, repeatability, process control, and inspection are some of the most important factors in creating high-performance products. At Interface, reliability and accuracy are the two most important features of our renowned force measurement products. For this reason, Interface continues to invest in the highest quality test and inspection technology to ensure each product that leaves the production floor is of the utmost Interface brand quality.
In this blog, we will be discussing our investment in top-of-the-line vision sensor technology and systems that help us to effectively reduce waste, improve efficiencies in manufacturing, and guarantee proper performance.
For many years, Interface has relied on our employees for their keen visual inspection of products that come off the production line. These trusted employees are looking at a number of things, including: are wires installed properly and are the serial and revision numbers correct. These respected and experienced Interface team members can inspect hundreds or thousands of products a day, with a heavy reliance on the human eye.
Interface load cells must meet stringent quality processing production standards, along with our calibration requirements before they are shipped to our customers. Interface will scrap any product that does not meet the exact precision standards for performance. In fact, if the product fails, we will not utilize the product at all. We will start our manufacturing process over to ensure the integrity and quality is met, as is expected with any Interface branded force measurement product.
In a recent experience of solving for a wiring issue that could cost thousands in waste, we sought out an innovative way to approach the challenge. To solve the visualization and human dependency concerns, we invested in a Keyence Vision Sensor IV2 Series. This camera system allows us to reduce human error by programming the camera to pick up misaligned wiring and notify the user.
It works with advanced sensor technology that can identify production issues and will provide the user with a green light if everything looks good, or a red light if there is an issue. The system is helping to significantly reduce both inspection time and production line errors. The vision technology system is currently implemented on our MBS mini load cell line, one of our highest volume production lines. Since implementing the system, we have not seen a failure that caused any type of loss.
We are now looking into how we could use the Keyence Vision Sensor technology in other areas of production. For instance, we are testing how the camera could be used to read serial and revision numbers that are laser marked onto our products. Every once in a while, if the laser is misaligned or the user hits an extra keystroke, the numbers could be off, and the customer will have an error in their records. With the innovative visualization system, the camera’s sensors could read the serial numbers and let the user know if there is an error quickly.
To learn more about how Interface is investing in innovation and technology to improve our processes and production methods, check out the IQ Blog at www.interfaceforce.com/blog/. You can also learn more about Interface’s 2019 Arizona Manufacturer of the Year Award here.
Contribution from Nick Siegel, Design Engineer, Interface