Critical Dimensions Inspection of Incoming Components

Customer significantly increases testing coverage of precise plastic parts; gets valuable insights on plastic injection moulding process

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We manufacture millions of products each quarter on its multiple fully-automated assembly lines. We are constantly looking for ways to improve raw material inspection capabilities in order to further improve the manufacturing yield.

Saccade Vision has demonstrated in a very short time excellent performance, flexibility in inspection of multiple components, helped us to increase the testing coverage and provided valuable insights on raw material quality.

S&P 500 Electronics Manufacturer,

Director of GLOBAL AUTOMATION

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Saccade Vision system was installed
in the manufacturing facility in Northern Israel
on the manufacturing floor near plastic injection molding machines.

Лазерная резка стали

BACKGROUND

The essence of the the customer’s reliability strategy is a physics-based multi-level method of failure point identification. Providing a warranty for a multi-year system operational lifetime was enabled through a combination of reliability-oriented design rules.

To verify that each product that leaves manufacturing plants conforms to its high reliability and quality standards, components, sub-assemblies, and final products are tested multiple times during production.

These rigorous screening and testing procedures, which are completed for 100% of products the company makes, enable to guarantee that its products work as expected for the entire product lifetime.

The company is also constantly working on improving the testing of raw material, components and sub-assemblies.

OUTCOMES

DATA ANALYSIS EXAMPLE

+60%

increase in measured data
per part

Precise

Universal

Insightful

All

critical dimensions were measured in
a single TAKT

increase in testing productivity

10X+

increase in data collected for
the process control and predictive data analytics

16X+

different applications were successfully inspected on
the same system

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CHALLENGE

SOLUTION

One of the main points affecting the overall manufacturing yield and the life-long reliability of products is the ability to keep the manufacturing of individual components inside tight specifications in terms of critical dimensions.

For example, very tight mechanical tolerances are required for good mating of plastic parts to ensure good encapsulation for multi-year warranty.

Another significant aspect is manufacturing automation. Imagine parts that do not fit well one inside the other due to mechanical tolerances. While human operator may use some additional “force” to make these parts fit, the robot will just stop. That results in lower productivity and eventually may be reflected in the top and bottom lines of the company.

Another critical need in 100% automated quality inspection is the ability to find the root cause for manufacturing quality issues as fast as possible, eliminate it and restore normal operation. Such root cause analysis, powered by AI, relies on massive high-quality data coming from automated dimensional inspection systems.

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Saccade Vision’s fast, precise, and flexible dimensional inspection system addresses the above challenges one by one. It dramatically simplifies the system design and thus cost. It offers unique, patent-pending technology for a more flexible, more accurate, and faster 3D quality inspection:

Flexibility and Ease-of-use:

Local optimization of illumination per feature, enables multiple applications on a single Saccade system. The integration of Saccade sensor is  very simple as it does not require any additional motion system.

Precision and Robustness:

Saccade Vision provides local resolution of the 3D point cloud of an order of magnitude better than any comparable solution in the market. Saccade Vision sensor works on stationary object, eliminating vibration errors and imprecise motion.

Measurement speed:

By focusing only on important locations, we can speed up the data acquisition significantly. Saccade sensor outputs high resolution point clouds only where it is required; The sensor performs calculations using low power single board computer.

OUTCOMES

The table below summarizes outcomes of Saccade Vision installation:

KPIs

Current QC procedure

Saccade Vision

Measure all critical dimensions (8)

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*

*some dimensions cannot be measured with a single tool requiring complicated testing strategy

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increase in measured data per part

+60%

Reach maximum QC testing capacity

(ideally 100%)

Current: 4 samples / hour

20 QC Testers required for 100% coverage (unrealistic)

100 samples / hour (during pilot)

100% coverage (with fully
automated inspection and 
zero HC)

increase in testing productivity

10X+

QA Data automation and process control

Only First Article Inspection (FAI)

Both FAI and ongoing process monitoring

more data for
process control

16X+

Minimize number of tools used for QC and simplify QC inspection

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different processes with the same system

Massive data obtained using Saccade Vision system enabled provided valuable feedback for further process improvement:

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Dimension 1

Dimension 2

Dimension 3