Redefining quality control with automated visual inspection systems

Overview

Automated visual inspection (AVI) is a quality control method in which products are automatically analyzed for inconsistencies through machine vision technology and artificial intelligence. Traditionally, quality control in manufacturing is performed through manual inspection. This visual inspection can have drawbacks. This is particularly true for errors like overlooking a defective product or falsely identifying a product as flawed, otherwise known as a false positive.

Optra’s automated visual inspection drives productivity in the production process by using computer vision to identify defects, lower production costs and shorten delivery time. Through the application of deep learning technology, AVI systems make informed decisions to distinguish between different parts and characteristics of a product while tolerating environmental anomalies. Optra’s technology detects defects quickly and consistently, regardless of scale.

Given the transformative effects that adopting automated visual inspection systems can have on optimizing operations, modern manufacturers should be aware of the benefits of using AVI.

Emulate human inspection and judgment

Even the best product inspectors have bad days. Loss of sleep, oncoming illness or any number of personal circumstances can affect the performance of working professionals. While most manual inspections adhere to well-defined guidelines for inspectors to follow, human beings are subjective in judgment. It isn’t easy to hold hundreds if not thousands of products to the same consistent criteria with the limits of human visual perception.

Optra’s automated visual inspection cameras can perceive a wider spectrum of colors and process visual information faster to make precise calculations. And by sensing dynamic range, the difference between the darkest and lightest points on a surface, cameras accurately scan unusual shapes and textures.

Determining where manufacturing equipment will be placed in a factory is a huge decision. Most production machinery takes up a lot of space, and accommodating new equipment may change the entire layout of the production floor. Thankfully, automated visual inspection systems don’t require much equipment to set up and can be deployed seamlessly into existing production processes.

All that’s needed is a machine vision compatible camera and the requisite software to perform advanced image analysis. This equipment can be easily added to most conveyor systems and production lines. Compared to other manufacturing equipment, Optra’s AVI system is easy to install, integrate and directly deploy.

Designed to meet and exceed variable inspection requirements

Calipers and micrometers have been the preferred tools of variable inspection for generations, but automated visual inspection technology eliminates the need for hand tool measurements entirely. By leveraging computer vision and deep learning, automated visual inspections can precisely measure dimensions and immediately identify variables and unwanted defects.

AVI technology is already delivering remarkable results for competitive manufacturers. The sheer breadth of visual quality inspection is possible with automated optical inspection using deep learning technology all but ensures success on the shop floor.

Important features and highlights

Automated visual inspection systems have outstanding features that make them preferable to traditional manual inspection:

•        Machine vision operates with significantly higher optical resolution than human vision

•        Can work in hazardous conditions that product inspectors can’t

•        Makes faster decisions and processes visual information more accurately

•        Remains objective and does not succumb to fatigue or distraction

The machine vision and automated visual inspection features allow for even the tiniest defects to be pinpointed without the inevitable fatigue that comes from performing hundreds of repetitive reviews manually. Evaluations can be made in a fraction of a second. Thanks to machine learning, the more visual information an AVI system receives over time, the better it understands how to achieve optimal outcomes.

Capabilities

AVI has capabilities designed to deliver the best possible outcomes in production line automation. Advanced AVI computer vision technology can:

•        Measure and sort quickly, determining that all parts are at the right dimensions and in the proper position

•        Examine surfaces for any irregularities or contamination

•        Decide the position of an object to precisely apply labels

•        Verify visual information like QR codes, bar codes or product colors

•        Assist in sorting and assembly processes, matching products to the corresponding packaging

Automated visual inspection is meant to perform the role of the ideal product inspector, assuring consistent quality in every aspect of the product. But Optra’s AVI capabilities go far beyond that. The speed and accuracy at which quality evaluations can be made far exceeds the capabilities of the sharpest eyes. If there’s any visual component to a product, AVI systems can detect and measure it.

Typical applications

Though AVI is primarily concerned with quality control, automated visual inspection applications in manufacturing are broader than one might expect. Beyond visual evaluations with computer vision, AVI applications can perform more sophisticated tasks, including:

•        Accumulate data using deep learning to find bottlenecks and improve efficiencies in other stages of the production process

•        Perform an extensive variety of tests by comparing visible output against expected results

•        Guide other robotic or automated systems in detecting errors and changes to environmental conditions

•        Analyze products across key metrics to identify errors in virtually any visible aspect

These applications have been adopted into complex industrial systems by manufacturers in any number of industries, from pharmaceuticals to automotive and more.

Benefits

It’s clear that AVI is incredibly useful for manufacturers looking to reduce errors and increase productivity. But the specific benefits of AVI are compelling enough to entice even the most skeptical manufacturers.

Reduced errors, increased inspection rates

An automated visual inspection system can do more work at a higher rate of efficiency than its human counterparts. Automated inspection systems with machine vision can achieve 100% inspection of parts, while even the most skilled human inspectors can hope for about 80% at best. More distinct parts, and the minute details of those parts, can be analyzed at lightning speed. 

100% compliance rates

Correct labeling is significant for certain products, particularly in the pharmaceutical industry. Adopting AVI can ensure that all labels are accurate and applied in the proper location, eliminating the worry that comes with accidental noncompliance to pharmaceutical product standards.

Improved processes

Optra’s automated system gathers consistent data and is a tremendous asset for finding flaws and vulnerabilities in your manufacturing process. The more data a visual inspection system consumes thanks to machine learning and neural networks, the better it understands desirable outcomes. Whether it be obstructions in assembly, warehousing, or any other department, errors and waste apparent to AVI can help manufacturers locate problems in their processes and adjust resources accordingly.

Reduced costs

Besides driving efficiency in quality control, an automated visual inspection can lower costs by reducing the need to hire dedicated product inspectors. Using AVI as part of the manufacturing process almost completely eliminates the potential cost of additional production runs to correct defective parts. 

Industries we serve

Automated visual inspection technology can make a substantial difference in business operations. Our Optra and AI solutions have been successfully adopted in many industries:

Manufacturing

•        Retail

•        Financial Services

•        Healthcare

•        Education

•        Government

•        And More

Optra can help improve your operations from all angles, giving you the confidence to scale production without fear of scaling defects. Using our parking spot tracker technology, you can optimize your shipping and transportation by monitoring vehicles in your lot and automatically identifying available parking spaces.

Optra’s automated visual inspection systems have revolutionized quality control in manufacturing, assuaging long-held fears that come with product defects and improper labeling. As our technology continues to evolve, further improvements are sure to lead to even greater efficiencies. If perfecting production is a concern for your manufacturing operations, there’s never been a better time to adopt AVI.