What is the role of automation in improving quality control for Consumer Electronics?

Now a days manufacturing is becoming complex in regard of component size and layout. Also the application is becoming more complex and severe. A small component failure can cause severe disaster to human life. Automation like AI based camera, humidity control etc. can make sure detection and prevention of failure, for which human manual control reliability could be questioned mark.

utomated quality control improves inspection measurement reliability. Accurate measurements on complex parts and high throughput production lines is assured with automated inspections

Automation is the best way to avoid fatigue of operator. So, the operator should be able to focus on the variations in the process. Manual work on repetitive work usually make operator bored and then skip some deviations happened. With automation, operator can handle variations more skillful as more time on digging deeper on the problems. Better products and lower down time can be probably achieved in long term. Meanwhile, the engineer can also collect better insight from the operator on actual production issue. The engineer will get better input for future improvement of the product design meeting automation.

In some applications automation such as scanning the parts throughout the manufacturing process helps not only in tracking the part(s) but it should eliminate mistakes in part picking and shipping. Some companies have several thousand parts, some witch might only have slight variations form one part to another. You would be surprised at the number of companies that still do this process manually.

The most important feature I think automatization adds is control and reduction of variation in order to keep quality and standarization.

In my experience working I've found optical CMMs to be extremely beneficial. Automated measurement via CMMs both tactile and optical have tremendous worth. They allow for proper datum structure usage when otherwise specialized fixtures would be required to set up a part correctly. Automated measurement also allows for better control of how a product is measured, removing the human variable from the equation. It also makes repetitive measurements of AQL samples extremely efficient. I've created programs that cut 8 hours of work down to 20 minutes of run time.

Consumer operates the electronics products by programming the controller to perform the required functions, including timing (ovens, dryers), power levels (microwave ovens), input channels (video recorders), and other cycle options (washing machines). Advantages commonly attributed to automation include higher production rates and increased productivity, more efficient use of materials, better product quality, improved?safety shorter workweeks for labour, and reduced factory lead times. Higher output and increased productivity have been two of the biggest reasons in justifying the use of automation.

improves the speed and accuracy of the inspection and testing processes. With robotics and other automated equipment and software, manufacturers can more quickly and accurately pinpoint product issues and defects during production as quality control position before leaving to be a supivisor

Implementation of quality control is best when done with the design team. A lot of problems can be avoided if the design team make suitable provision for testing early in the design, this avoids constraints caused as the design matures. Even something like optical inspection can be optimised by the design engineers being aware of the requirements of the vision system. Early choice of test points and if at all possible fixing their locations early, makes it possible to build ATE fixtures in parallel with development, you can even get the design team on side, if that ATE can be used in validation and verification testing.

Automation for quality control can have large upfront costs but are very worth having. However, they need to be managed well. If someone is programming them it can be very easy to get a result that is not accurate. There is a need for deep understanding of certain aspects of the software the machine uses, as well as applicable industry standards such as GD&T. Automation is only as good as the programmer and operator, and as always, these machines need to have regular validation to standards. Also, performing a gage R&R will save a lot of headache with validating a measurement method.

Appropriate level of automation in consumer electronics directly depends on production volume. In simple terms - robotics is justified at 1M+ units production runs when every minute of machine time generates profit. Consider the entire pipeline and bottlenecks: automated Quality Control with Vision system, X ray, and functional tests makes sense when assembly line is also fine tuned for maximum throughput. At low volume manufacturing (<10,000 units) assembly is primarily manual and low degree is automation is involved. At medium volume production (~100k units), human labor is augmented with local automation techniques to assemble and test devices. Last, as production moves to countries with higher labor cost, demand for automation grows!

Appropriate level of automation in consumer electronics directly depends on production volume. In simple terms - robotics is justified at 1M+ units production runs when every minute of machine time generates profit. Consider the entire pipeline and bottlenecks: automated Quality Control with Vision system, X ray, and functional tests makes sense when assembly line is also fine tuned for maximum throughput. At low volume manufacturing (<10,000 units) assembly is primarily manual and low degree is automation is involved. At medium volume production (~100k units), human labor is augmented with local automation techniques to assemble and test devices. Last, as production moves to countries with higher labor cost, demand for automation grows!

I am a big fan of the "plug-in" approach (as in software plug-ins as opposed to a cable). Ease of depolyment for integrators is crucial. When a Control System has invested in the technical partnerships with peripheral manufacturers, ideally following some sort of development standard, the benefits for deployment are priceless. Happy integrators leads increased sales as a preferred "go-to" technology.

In my time at my current employer, we started doing twice weekly validations/requalifications of our tactile automation. And I've implemented requalification of our touch probes on or optical CMM once weekly. In my use of the machine I found the probes to regularly be out of alignment with the optics. A calibration sticker may have a year but the system should continuously be monitored.

Process automation is a key ingredient in continuous production process high enhance accuracy and consistency in quality of product. It helps improve accuracy in weighing, dosing and other process conditions.