automated optical inspection training

8/11/2019 Automated Optical Inspection training

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Automatic OpticalInspection

MALTA


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WHAT IS AOI ?

AOI stand for Automatic Optical

Inspection.

The AOI system checks the boards to

ensure that the components are present,

not skewed and are located properly in the

X and Y directions.

It checks component polarity if clear

orientation marks are present on the

component body.

It even checks 2D paste deposition also.

And displays result.


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MACHINE OVERVIEW


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Modelling and Detection

Sometimes industry and academia refer to

the same concepts differentlyA Unified approach was developed for dealing

with scheduling problems using available data

Our approach is based on a graphicalrepresentation

Modelling allows us to

find out

which problemsrequire academic

attention

help us find existing

research


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Optimisation

Providing a generic optimisation tool for diverse

production line is very difficult The focus is on scheduling orders, not planning

Tools must be adaptedfor individual productionlines

Suitable for fast scheduling and what-ifanalysis Example in case of

machine breakdowns or

for configuration changes


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Optimisation

Tools Provided

Optimisation of Single Machine problems

Very common for SME manufacturers

Optimisation of Job Shop Problems

Very common with Multi-Stage Production Lines

Handling of Parallel Sequences

When some sub tasks are done inparallel to the main task to speed

up process (e.g. preparation of

basic components)

Handling to setup time between

different jobs Machine Reconfiguration

Support for release dates and

deadlines


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Defects

Missing or incorrectly placed components

Scratches and cracks

Print offset, missing/extra transfer of ink Smudges and misalignment defects

caused by multiple printing on location


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An Automated Inspection System

Reliable 24x7

Accurate

Fast

Consistent

Cheap


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Automated Optical Inspection

Image

capturing

Image correction,

background

removal, alignment,segmentation

Further image

processing and

feature extraction

Data Input to

Classifier and other

QA tests

Output from

Classifier


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Setting up the system

The system can be configured

to perform a number of QA

tests depending on the product

and type of defects

A product representation is built by the system

based on one or more of the following

A single product and some parameters A number of defect free samples

Both defect free and defective samples


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The two steps of AOI

System is split up into two main modules Image Processing

Alignment

Background Removal

Segmentation

Inspection

Feature Selection

Colour Inclusion

OCR

Label location

Neural Networks (WISARDs)


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Practical use of ICT in

ManufacturingA Case Study

Testimonial: Mr Olaf Zahra

Toly Products Malta


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Toly Products is cosmetic packaging solution provider for the

beauty industry.

Toly Products has been manufacturing in Malta for the past

40 years. Today the majority of corporate function are also

located her.

Our factory here (and in other countries) operate on lean

manufacturing principles. We manufacture only to order on

the date the product is required

We produce between 1.5 to 2 million units per week

We have over 2,500 different live products


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Research Benefit Scheduling is a critical function:

Impacts manufacturing efficiencies. Impacts delivery and customer satisfaction

Impacts reputation if deadlines are missed

Good scheduling requires

Skilled operators who know the processes well

Involvement of several key departments and functions/

Good regular feedback from the production floor.

Since 2008 this criticality has increased exponentially. In adownturn, organisations try and release cash and in our industrythis was done by reducing stocks. As the market recovered thenew limits set on stockholding have been maintained. For anupstream manufacturer this means shorter runs and morefrequent changeovers.


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Major Challenges

A lean manufacturing set up requires components to becontinuously in motion from the beginning to end of the process to

avoid bottlenecks and the build up of stocks. It also requires

materials to be delivered to the production floor when and as

required.

A large variety of products for different clients A bewildering combination of mould tools and moulding

machines that need to be configured for different jobs

Finding a good balance between technical and human

constraints and meeting client demand

Delivering to the customer On Time and In Full. The aim is to

Minimisation of downtime

Minimisation of work in progress

Maximising resource utilisation


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Exploring Possibilities

Achieving better results while maintaininga flexible manufacturing environment

Explore different possibilities of

allocating resources to manufacturing Gain future insight to help sales and

marketing personnel plan orders

Work around scenario changes in casesof schedule disruptions (e.g. urgent

jobs)


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Achieving the target

Having several scheduling possibilities allows formore accurate planning.

Functions have better visibility of the tasks they

are required to perform to service the plan. Minimising job changeovers reduces delays and

maximises overall plant efficiency


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Benefits

Some of the benefits offered by thesystem

Effective planning tool

New approach to scheduling Cost Effective

Fast Results

Configurable

Low training requirements

Uses information we already have and know

about


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Process 2Automated QA

for Print Output

using Neural Networks


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Visual Inspection at Toly

Production of luxurycosmetic packaging for thebeauty industry.

Visual quality is of utter importance

Even using state of the art machinery there are a

multitude of parameters therefore variation is a fact oflife. Inspection needs to identify this variation before itexceeds the permissible tolerance so that defectivesare avoided and the process can quickly be broughtback in line.

Visual defects consist of Bad Printing (location, missing/extra ink)

Incorrect assembly.

Scratches, cracks or smudges


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Challenges in the inspection process

Currently visual inspection is carried our in one of two ways

Manual Inspection Advantages

The inspector can identify and classify small variations from product to productand take a call; i.e. is flexible

Drawbacks Tedious

Inconsistent Slow

Inaccurate

Current (at Toly) camera based automated inspection technology Advantages

Accurate

Consistent

Fast

Drawbacks Limited application.

Inflexible; it works with strictly defined parameters therefore typically will rejectnumerous good parts with the bad parts


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Using the system

The system is configured with fewparameters and provided with a number ofdefect free products.

System then trains and builds a multi-layered model for that particular product.

The model is saved and used every time

that the corresponding product ismanufactured avoiding the need ofreconfiguration


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Benefits of the system?

The system is able to identify defects on our

products from several good and severalbad

images. Therefore it builds up a memory of

good parts which allow it to widen itstolerances over traditional systems.

It is applicable to a wide range of products

and also a wide range of defect possibilities. Easy to set up and easy to update once a

new defect has been encountered.


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Summing it all up

The system is preferred over manual

inspection

Reliable

Avoids manual contact of the product

More accurate

Faster Consistent


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Thank you for

listening

automated optical inspection training

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