Inspection & Defect Detection

Automated inspection and defect detection systems are becoming more vital to business survival not only because of the obvious cost savings in finding defects, but also for maintaining competitive advantage by rapidly identifying and modifying less-than-optimal manufacturing and quality control processes. As a result of significant leaps in technology over the past few years, automated inspection using high speed machine vision and digital recording, processing, and analysis solutions is no longer financially or technically out of reach for most.

Today, many tasks previously thought to be too complex for automated inspection are being transitioned away from humans for a variety of reasons. The sheer speed of operations is one of the most obvious.  When you need to inspect thousands of products or parts per minute, or if you simply want to know what happened when a high speed machine or process breaks down, a high performance automated system is the only solution.  Harsh environments are another area for automated systems deployment. Toxic or difficult environmental exposures put both humans and companies at long term risk.

With the integration of various types of sensors (visual, and non-visual), correlation of data involving all kinds of measures is possible, providing remarkable new insight into product manufacturing and quality control and assurance. Complex analysis of this data can be done at extremely high data rates in real time resulting in rapid and reliable information for decision making.

One of the primary tools in the arsenal of examination and remediation is video imaging.  High resolution cameras with appropriate optics for the application are able to capture much more detail than the human eye in almost all situations. Consider the possibilities of using multiple high speed, high resolution cameras capable of closely examining objects from multiple angles to reveal defects and behavior, all of which are synchronized to give you a 360 view of a machine, a product, a part or a process. This does not take into account the ability for cameras to capture the “unseen” due to rate of movement or characteristics not obvious in the visible spectrum. And, unlike humans, these systems do not fatigue in a few hours.

There are additional benefits of automated systems beyond the requirement for inspection. For example, visual and non visual data can be combined for analysis, training, systems improvement, and product or process design modification. Typical issues revealed by modern automated inspection systems range from faulty materials to inefficient processes or methods. Machine Vision systems can also provide capabilities that humans cannot possibly match, such as aggregated real time data analytics. In addition, the inspection systems can be fully integrated with other produciton systems already in place to provide further cost and quality improvements. Defective item tracking and root cause analysis are other key capabilities. Defective items can be thoroughly tracked from the source of the defect to destination, enabling forensic follow-up and cure.

Another element in inspection and defect detection is sorting and grading. Often materials and processes can be graded rather than being either eliminated. For example, certain products can be ranked in quality and sent to markets based upon the level of specification demanded. That is, variations in quality and/or tolerances may often find a market. Systems that grade appropriately can reduce waste and create new found business opportunities.

For example, look at an inspection system developed by Boulder Imaging for bottle and can production -The Quazar Canning and Bottling Inspection System (CBIS).

The CBIS allows the beverage or canning company to fully inspect every single product and process in the production cycle.  At any point if a problem occurs the system alerts appropriate personnel and directs them to the precise location where the problem is occurring.  The process engineer or plant manager can then address the problem in real time and correct it, thus preventing many minutes and thousands of products being lost or not produced.

The following areas are inspected:

1.  Bottle/Can Uniformity prior to arrival at the filling position.  Many products are thrown out because raw materials are defective.  In this case, pre-forms can be inspected and rejected before they go through the production cycle – not after.

2.  Fill Line and Valve function at the filling position.  At this stage, the system monitors fill line for each valve position.  When there is a problem, the appropriate manager or technician is alerted and can address the problem immediately.

3.  Cap Application.  At this stage cap application for every product is monitored.  Any malfunctions are immediately reported for repair.

4.  Label Placement.  At this stage, proper application of labels for every product is inspected.  Measurements can be made to 1/32nd of an inch of accuracy.  Again, any defects or malfunctions are instantly reported.

5.  Packaging Integrity.  At this stage, the CBIS monitors the packaging process.  6, 12, 24 packs (or any other packaging configuration) are monitored for count.  Problems are reported in real time for immediate repair.

6.  Package Print Registration.  As with Label placement on individual cans and bottles, this station monitors correct printing of labels on final packages.   Instant reporting is made for any malfunctions.

7.  Palettes.  At this stage, the correct loading and stacking of palettes is monitored and, where problems are encountered, an alert is immediately sent to the appropriate manager or employee.

The Quazar CBIS consists of a number of industrial, high speed cameras that capture all of activity on the production line and send data to the Quazar recording and analysis station.  As the cameras and station are completely independent of the production machinery, there is no need to integrate the CBIS with any other system.  That is, it is a stand-alone inspection system that simply watches the production activity and reports when there is a malfunction.  This is done by the image analysis software that is able to determine, in real time, when an action is not standard and, therefore, needs attention.

Where needed, appropriate lights are set up to best capture the video data.  For the most part, low-light cameras are used, thus minimizing the need for additional lighting. The data captured by the cameras is transmitted to the Quazar recording and analysis station via 1 or more unobtrusive Ethernet cables.  The recording and analysis station is the brain of the system. It recognizes when an anomalous event occurs and alerts a single person attending the station to any of the seven areas being monitored.  Alerts can also be sent via a normal computer network to anyone else inside or outside of the production facility, for example the plant manager and/or one or more technicians.

Boulder Imaging Exceeds Your Inspection & Defect Detection Needs

Boulder Imaging can deliver the full range of services associated with implementing an integrated solution for inspection and defect detection. We develop best of breed solutions to specifically address the needs of our customers. With the flexibility to address very complex and specific demands, we have an unsurpassed reputation. Whether it is analyzing, defining, creating, implementing, or fine tuning, Boulder Imaging is your partner of choice. To learn more about Inspection & Defect Detection and how Boulder Imaging can assist your organization in addressing its particular needs, please contact us by This e-mail address is being protected from spambots. You need JavaScript enabled to view it This e-mail address is being protected from spambots. You need JavaScript enabled to view it