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defect detection in manufacturing

Ensure Employee Safety with Vision Intelligence System

Employee safety should be one of the major concerns of a business, especially in scenarios like todays. COVID-19 pandemic has driven this requirement to an extreme level. Factories are liable to comply with safety regulations set by the government. Inability to follow the same can lead to severe penalties on the employer.   However, some employees might not want to comply with them for not being comfortable enough. This unawareness may lead to serious health issues as well as internal disruptions. Employee injuries might hamper operations.   In small businesses, it is not so tough to monitor their employees. However, in larger firms where the employee count may reach 100+, it is not practical to keep an eye on every employee manually.  These difficulties lead to the need to be assisted by Automatic Vision Detection. A machine system that detects if employees adhere to the safety regulations ideally. Trident Information system has developed Vision Intelligence System, which ensures employee safety. It tracks each employee and maps employee faces into the dataset who takes their safety measures casually.   It is mandatory to comply with the safety regulations as its failure can land you and your firm into deeper trouble:   Financial Penalties  Industrial disqualifications  Endangering lives  Impact on the overall output   Reputation Damage    How Does the Vision Intelligence System Ensure Employee Safety?  This technology ensures safety measures compliance by monitoring each employee, recognizing their faces, and reporting to the person concerned about each one who fails to do so.   It ensures that the employees are maintaining the distance they have been asked for.   Vision Intelligence System Conducts:   Face Mask Detection   And Safety Gadget Inspection  Contactless Attendance   Social Distance Compliance Detection  Face Mask Detection  The camera tracks each employee. In case an employee does not wear a mask, it immediately recognizes his face and maps him and his details on the database. Thus, providing the information to the person concerned. The employer is no longer burdened with the responsibility of checking every employee randomly as soon as it is done automatically.   Safety Gadget Inspection   Like the Face Mask Detection, it spots each employee and checks if they carry their safety gadgets properly. Even partially missing gadgets will be detected. Again, those employees will be recorded, and thus saving their details within the dataset. Thus, later it will be delivered to the person concerned.   Contactless Attendance  The system records each employee’s face at the entry and marks their attendance. The first entry is the arrival time, and the final exit is the departure time. This way, the employer ensures contactless attendance. It happens automatically and saves a great deal of time.   Social Distance Compliance   As an employer, you do not even have to worry if each of your employees complies with social distancing norms. The system records employees who violate the standards and reports it to the person concerned.  Keeping an eye on employees becomes easier with automation. Since the employer does not engage with the employee, he can focus on other essential tasks focusing on the output boost. Employees are much safer and get a more hygienic environment to work in. hence, improving their capacity.   What Does the Vision Intelligence System Offer Your Business?  Vision Intelligence system ensures health and safety regulation compliance and keeps the employer away from all the fuss. He does not have to go on random rounds around the factory to ensure that everyone wears masks, safety gadgets, or maintains social distance. It ensures the following benefits to the firm:   Protects your staff: Its primary job is to protect your employee from any injury or harm occurring in the workplace. It ensures the employees adhere to the standards and have their safety equipment like masks, harnesses, caps, etc. on to avoid COVID-19, back pain, head injuries, asthma, and so on.   Reduces Absences: safe employees are present on-premises and barely take leaves due to injury, disease, or similar reasons. The employer saves costs of the direct absence, such as paying salaries.   Boosts Productivity: Now the employer is not liable to keep a constant eye on employees to see if everyone is following what they are told, nor does he have to engage extra employees to fulfil this duty. Automation does all the work and leaves enough time and strength for the resources to focus on more important tasks.   Tracking each employee all the time is a pain. Manually it becomes even harder. However, automation can save you. Trident Information Systems has developed and designed a Vision Intelligence system for defect detection while manufacturing and maintaining employee safety. Contact us for further information. 

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Reshape Your Quality Process with Vision Intelligence System

Since the manufacturing sector in the Indian economy counts about 17% at current, it indeed is prominent. However, Manufacturers, these days are mounted with tremendous pressure to provide quality as well as speedy production. If done in silos, it can be time-consuming, especially the quality check part, which demands more labor as compared to a Vision Intelligence System.   Quality control is what many manufacturers struggle with. The traditional belief of quality check as a labor-intensive task blocks the countless opportunities crossing their paths. These days, one of the key issues contributing to the issue is a labor shortage. This pandemic has driven the gap to the next level, mounting existing employees with additions to the scope of their jobs assigned.    Other than this, traditional quality inspections might come up with issues like:  Monitoring different parts and materials makes it harder to handle quality control for complicated products  Inability to identify the distinct spectrum of colors.   Human eyes might miss minute errors like small scratches, dust particles, and so on.   Lack of resources and time might compromise product quality.  What is a Vision Intelligence System, and How Does it Work?  Vision Intelligence System is a product designed by Trident Information Systems specifically for manufacturers. It automatically detects product defects like scratches, dust particles, broken pieces, etc. straight from the conveyor belt with least or no human interference. But how does it work?  Our computer vision engineers first understand the issue/customer requirements.   Then they collect data in the form of images, followed by developing algorithms and models.   They then test the hypothesis / validate the models.   After testing and finalizing every step they either offer POC (Proof of Concept) or proceed for onsite implementation (according to the customer’s requirement).  Trident’s Vision Intelligence System Covers seven industries, i.e., automotive, retail and FMCG, packaging and printing, pharmaceutical, glass, laminate, and cement.   Automotive Industry: Automotive manufacturers can classify different product variants based on color, shape, design, size, and so on. It also detects visual defects like a dent, scratch, burr, chip, etc. Vision Intelligence System can read barcode labels and 2D barcodes directly from the marked parts, verify labels as well as direct part marks. Additionally, they can detect wrinkles, dents, cracks, and piston defects.   Retail and FMCG Industry: With the help of this technology, you can check the structural quality, operational quality, and dimensional accuracy within seconds. You can assure accurate ingredients and standard quality. You may also detect foreign particles like dust, stones, insects, little animals, and so on.   Printing and Packaging Industry: With VIS, you can spot packaging defects such as improper passing, irregular packing, torn parts, and so on in FMCG products. Enable high-speed detection straight on conveyors, spot missing components, read QR codes and barcodes, classify products, and a lot more with optical and thermal camera vision.   Glass Industry: Being one of the most brittle materials, glass needs extra care. Identify inaccurate logos, scratches, breakages, cracks, air bubbles, etc. Ensure all the parts are glued properly and check if the logo has been printed as it should be with VIS.   Laminate Industry: You no longer have to deal with the risk of dispatching defective sheets. Ensure accurate chemical composition during the mixing process. Identify laminate placements, pick-up operations, machine alerts. VIS also helps identify raisin spots, dust, design defects, and mosquito defects.   Pharmaceutical Industry: Manufacturers of medical devices, bioscience products, and pharmaceuticals need cost-efficient technology to check the quality. You can control the packaging quality, check fusion bottles, and track your products more precisely with the Visual Inspection in Manufacturing.   Vision Intelligence System for Employee Safety  Vision Intelligence System for Employee Safety ensures safety of your employees. It has two segments dedicated to the section, i.e., Face Mask Detection and Safety Gadget Inspection. In both cases, the system spots employees not adhering to safety standards.   The Face Mask detection solution (FMD) comprises two main branches:   Mask Detection – which detects employees wearing masks.   Face Detection – The system recognizes faces not having masks on and maps his face followed by the employee’s details in the database.   The employer can also conduct contactless attendance: when a person comes to the institute, wait for a little while and let the camera capture their image. This solution then recognizes the employee’s face and marks his attendance. It considers the first entry as the arrival time and the last entry as the departure.   The other one is Safety Gadget Inspection, where the system identifies if the employee carries safety equipment that has been allotted to him. It detects partial compliance as well such as – no helmet, employees without a harness, and so on.   Manual Inspection is bound to limitations. It is a lot more labor-intensive as well as time-consuming as compared to automatic defect detection. Trident Information Systems offers a robust Vision Intelligence System reinforcing manufacturers with automatic technology detecting defects more precisely while demanding least or no human interaction. Thus, filling the labor shortage without burdening existing employees. Contact us for further information or a demo.  

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How Does a Smart Visual Quality Inspection Ameliorate Manufacturing?

Whether you manufacture cars, food beverages, laminates, or medicines, production quality and yield are two of the industry’s top performance metrics. A Vision Quality Inspection can help you detect any defect at once, and save you a money drain from recovering faults, generated scrap, lifted work in process inventory, decreased yield, post-sales warranty, recalls, claims, and repairs. You might end up dealing with all of it.     Problems with Current Visual Inspection Approaches     Manufacturing is a multi-layered process where an item’s visual inspection might include more than a step. Usually, visual inspection is utterly manual and a time-eating process that lacks consistency due to other factors.     Manual inspections are done by experts with diverse backgrounds and different experiences. Therefore, different inspectors might have different opinions on a product’s quality. This situation may lead to a lack of consistency.     A traditional quality inspection might require inelastic systems that might fail to comply with the product’s modifications.     Common machine inspections can only detect a handful of defects at a time.     To help manufacturers produce more accurately and cost-efficiently, Trident Information Systems has brought Visual Quality Inspection. It is a purpose-built Machine Vision System plus our best Artificial Intelligence combined, for Automotive, Pharmaceutical, FMCG, Laminates, Cement, and Glass.    Impact of a Smart Visual Inspection on Your Business    An automatic Visual Inspection in Manufacturing spots detects right on the conveyor. Its HD vision camera never misses a fault. Unlike manual inspections, our Automatic Visual Inspection cuts corners and leaves you enough efficiency to spend on other productive areas. Witness a boost in quality and production with this automation. Cut costs and enhance overall factory production.     Production Boost    Unlike manual inspections, an Intelligent Machine Vision System detects defects straight on the conveyor, detecting minor detects like scratches, slight discoloration, small tears, dust particles, and so on. The inspection process catches pace and leaves you and your staff enough time to focus on other KPI (Key Performance Indicators)    Enhanced Flexibility       The advanced automatic Defect Detection in Manufacturing technology comes with flexibility. You can integrate it with either your existing surveillance or get a fresh set of cameras. Additionally, the system gets accustomed to product modifications quite easily. In other words, if you decide to make slight modifications to your final product, the machine can easily get accustomed to it.     Greater Accuracy    Human eyes may miss certain defects, but machines do not. Even if there is a little scratch on a glass product, the machine quickly detects it and displays an alert on your computer screen. It ends up ensuring production efficiency and quality rise. Analyze the defects straight away and make necessary corrections.     Remote Access     The best part of vision quality inspection is its remote access. You no longer must be there around the conveyor belt to ensure every product is finely manufactured. Simply, sit in one corner and track all the levels of manufacturing. It enhances efficiency and quality. As soon as there is a defect, the system flashes an alert on the screen, so you quickly notice it and prevent further defects.     Labor Cost Reduction      Vision Quality Inspection cuts labor costs since everything is handled by machine and minimum workforce monitors end-product quality. Optimize your labor in different production sections where machines cannot play a part.     Standard Detection Consistency      In manual inspections, the inspector detects defects reflecting their point of view and past experiences. Hence, different inspectors might have different viewpoints which lead to inconsistency. However, this can never be the case with Visual Quality Inspection.     Why Should You Implement Trident’s Visual Quality Inspection?   Our Visual Quality is designed specifically to detect minute defects your naked eyes might miss. Coupled with digital sensors, RFID (radio frequency identification) tags, QR codes, and a high-definition camera, no defect can slip through. With optical sensors, it captures images and transmits them to computers for further processing.    Trident’s VQI enables the following solutions supported by optical camera vision, thermal camera vision, and X-ray vision:    Visual Defect Detection.     Presence absence of components    OCR    Barcode and QR code reading   Classification of products    Relative dimension monitoring    High-speed detection on Line/Conveyer     Visual Quality Inspection Process     Captures environmental conditions    Captures pictures of good products and defective products.     Augment and classify defects vs good product images.     Annotate defects in images.     Simulate environmental conditions.     Training the AI Model    Test classification accuracy and confidence level.     Deploy model for production inspection.    Industry Use Cases     Trident covers six Industries i.e., Pharmaceuticals, Cement, Glass, FMCG, laminates, and Automotive. Our flexible and Intelligent Machine Inspection focuses on each of their requirements and serves accordingly.     Pharmaceuticals     Track defected, missing, chipped, or powdered tablets or foreign tablets. Inspect the quality of stopper seals, containers, crimps, and caps, also check the filling level. Real every industrial code, inspect labels, read, and verify optical characters (OCR and OCV).     Cement     Monitor the accurate cement shade, ensure it is uniformly grey with a hint of green shade. Ensure the cement does not have any lumps forming due to atmospheric moisture. Check the cement texture precisely and detect any adulteration like sand particles and dust that may disrupt its smoothness.    Glass     Identify any distortion or refraction on the windshield, side glass, and so on. Also, check patches, scratches, dust, and marks. Inspect the proper printing of logos. Measure accurate dimensions and check any irregularities and distortions.    FMCG     Detect foreign components such as small insects, dust, stone, unwanted vegetable components such as thorns and wood. Check structural quality and dimensions, ensure the presence of required components. Monitor color accuracy and measure the product’s intensity along with the spectrum of the object’s illustration.    Laminates     Spot subtle defects such as resin spots, foreign particles, dust particles, mosquito defects, and design thorns while eliminating human efforts. Check the sticking barcode’s efficiency and sheet classification. Monitor solution levels, weights, and temperature within the tanks via Intelligent Machine Vision System.    Automotive     Read barcode labels and 2D barcodes from the marled parts, detect labels, and Direct Part Marks (DPM). Identify cracks, dents, and wrinkles in any part during the manufacturing process, also recognize piston defects. Measure part’s dimensions such as inner or outer diameters of O ring. Check

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Why are Manual Inspection Methods Not Effective Nowadays?

Have you been considering manual Defect Detection in Manufacturing so far? Don’t you think it is high time to switch to automation for faster and better-quality products? You are most likely to fall behind in the competition if you keep putting most of your time and resources into manual testing that does not even guarantee accuracy in some cases.   Manual testing might work in some areas, but it is not preferred every time since it comes with various drawbacks such as:   Low Accuracy   Humans are prone to make errors, and manual testing is more likely to make more errors than an automated solution. For example, in the case of glass manufacturing, human eyes might miss dust particles in a hassle, or they miss subtle scratches appearing on the glass surface. As soon as they notice it, there are chances the defective pieces have already found their way ahead.  Mandatory Human Interactions   In current times, where social distancing is the topmost priority, we need to avoid human interactions as much as possible. Batch testing (executing a series of tests) is possible. However, in each test case execution, human interaction becomes inevitable. If you switch to a Defect Detection Computer Version, everything gets automatic and needs no/less human interference.   Demands More Time and Resources  To cover each application area, you need to perform more Manufacturing Defect Detection tests. Creating test cases and their respective execution eats up a great deal of human effort and time. Checking up on each product, and informing the concerned person to take relevant steps, and taking up the same tests, repeatedly, can be exhausting and time-consuming.  Impractical Data Collection   Unnecessary data collection is one of the biggest drawbacks of manual inspections, collecting and comparing substantial amounts of data is impractical without automation. Preparing reports on products and reporting them to the relevant personnel can be time-consuming and prone to errors.   How does an automated intelligent machine system help?  The demand for higher productivity and better-quality output within the manufacturing industry has demanded an upgraded production inspection. A Visual Inspection in Manufacturing is more beneficial; you can assure better and faster defect detection. A Machine Vision Inspection can offer tremendous benefits such as:    Boosts Manufacturing Output   With automatic vision inspection, you can detect defects faster and make necessary modifications, you no longer must put your time and efforts into manual testing and reporting, instead spend it on other productive tasks and get a boosted ROI. The inspection is done in one station and there is no need to set multiple inspection sections.   Minimizes Inspection Time   In visual quality inspection, everything is done by the machine itself so you do not have to fuss on its accuracy and speed. There is no doubt that the machine version surpasses human vision in every level provided by its speed, repeatability, and speed. Machine vision can easily identify small objects and detect defects with lesser errors and reliability. Machine vision can inspect thousands of products and their parts in a minute on a production line.   Better Perception   Machine vision has a high resolution depending upon the technology and hardware that are being used for the object’s illustration. Automatic Defect Detection in Manufacturing has a better spectrum of visual perception. Moreover, the system is more reliable and can be programmed as required.   Anywhere Deployment   Such systems can be deployed anywhere, even in locations that are hazardous for humans. It is best for manufacturing products or solutions that may cause serious health hazards or injuries to humans.   Production Optimization   With this technology, you can easily interpret defects and solve them in the closest time possible. Analyze first output and resolve the core issue of the quality defects. You may as well use the permit fixers to highlight defective components and effectively digitalize the defect reporting process.   Promotes the Desired Outcome   With a Machine Vision Inspection, you can optimize your products and workforce. You can also eliminate the need for sampling products while using this technology. Also, you can revise all the defective products from the data storage and identify the root cause of defeated data in real-time. Automating these activities can make your production goals easier to achieve.   Minimize Future Costs   You can easily cut costs with a digital quality inspection (including rejected or returned items that could be damaged due to shipment-oriented packaging defects). Remove them before getting shipped and improve the end customer’s product quality experience.  Final Words   Manual Defect Data Detection in Manufacturing has become outdated. Automating your quality inspection can eliminate all the issues arising under manual quality inspection. Trident Information Systems is one of the best Vision Quality Inspection service providers.  

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