The influence of quality control in production optimization

What is Specular Zero?

This article defines the concept of Specular Zero, developed by ISR Specular Vision. This concept is born since ISR can automate the aesthetic inspection of components and parts with complex geometries, such as those produced by TIER 1 companies, improving both the digitization of quality control and the quality of the data generated.?

This level of quality control automation, together with the improvement in the quality of the collected data, allows the use of AI along with Big Data techniques to compare production quality with the main parameters of the production process, material, and environment, ultimately seeking the optimization of production parameters to achieve a better quality, energy efficiency, reduce the carbon footprint of the final product, and increase the associated production benefits.?

Specular Zero is based on pre-trained AI software that can make automatic recommendations for production optimization. For this purpose, quality data collected in the OIT Systems OIT Systems , developed by ISR specifically for inspecting components and parts surfaces, are cross-referenced with data from the Autonomous Production Units (commonly known as UAP). Production data, in these cases, includes all information generated in the injection molding machines, the ovens, the coating systems and any other processes involved in the manufacturing lines. Material data is marked by the manufacturer, environmental data is collected through various sensors located in the UAP or directly taken from an internet source, and injected geometry data (geometry complexity, surface concavity and convexity, thickness at various critical points, etc.) is taken from the part's CAD.?

How Specular Zero works?

The value of Specular Zero in the manufacturing sector is significant. The ability to detect and correct aesthetic defects in manufactured parts in real-time not only improves the quality of the final product but also reduces waste and reprocessing costs, which leads towards a sustainable production.?

The optimization of the production process aims to reduce energy consumption and the carbon footprint, which is crucial for worldwide companies committed to sustainability and innovation. The implementation of Specular Zero can translate into substantial economic benefits and a significant competitive advantage for customers, enhancing the experience of production and reinforcing its leadership in markets such as the automotive components, high value metal surfaces or glass.?

In summary, the application of the Specular Zero concept offers an advanced and efficient solution to improve product quality and optimize production processes, aligning with sustainability and efficiency trends in the industry. This approach ensures that the company's specificities and needs are addressed precisely and effectively.?

And how does it work? the model in Figure 1 illustrates the various factors and their interconnections in the Specular Zero concept, focusing on defect prediction, material and energy expenses, cycle time, and their impact on profit and pollution.?

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Inputs?

• Inspection Standard: The criteria or guidelines used to inspect and measure the quality of parts.?

• Material: The raw materials used in the production process.?

• Productive Process Parameters: The settings and conditions under which the production process operates.?

Defects Prediction?

• A central component that takes inputs from the inspection standard, material, and productive process parameters to predict potential defects in parts.?

• This prediction helps in improving the OK Parts Ratio, which represents the proportion of parts that meet quality standards.?

Energy + Material Expenses?

• The costs associated with the energy consumption and materials used in the production process.?

• These expenses are influenced by the productive process parameters.?

Cycle Time?

• The duration required to complete one production cycle.?

• Like energy and material expenses, the cycle time is also influenced by the productive process parameters.?

Outputs?

• OK Parts Ratio: The outcome of the defect prediction process, indicating the percentage of parts that are free of defects and meet quality standards.?

• Profit (k€/h): The financial gain per hour, which is positively impacted by a higher OK Parts Ratio and optimized energy and material expenses.?

• Pollution (g CO2 / part): The environmental impact, measured in grams of CO2 emissions per part. This is reduced by efficient energy and material usage and optimized cycle time.?

Flow and Impact?

• The Inspection Standard, Material, and Productive Process Parameters serve as inputs to the Defects Prediction process.?

• Defects Prediction improves the OK Parts Ratio, which in turn increases Profit and decreases Pollution.?

• Energy + Material Expenses and Cycle Time are directly influenced by the Productive Process Parameters.?

• Both Energy + Material Expenses and Cycle Time have a direct impact on Profit and Pollution.?

The model in Figure 1 showcases the interdependent nature of various production factors and their collective impact on the efficiency, profitability, and environmental footprint of the manufacturing process within the Specular Zero concept.?

How AI is used in Specular Zero?

The implementation of Specular Zero, developed by ISR, is based on the powerful combination of Artificial Intelligence (AI), particularly Machine Learning (ML) techniques, and Big Data. This section explores how these technologies contribute to the optimization of the manufacturing processes, achieving an improvement in product quality, ultimately leading to Zero Defect Manufacturing (ZDM). The use of big data and AI to help guide manufacturing decisions is a central aspect of ZDM.?

Specular Zero concepts, leveraging machine learning (ML) techniques and big data analytics, is anticipated to yield significant improvements across various facets of the production process. Key outcomes expected from this concept include:?

• Enhanced Product Quality: By analyzing vast datasets from production processes, ML algorithms will identify patterns and insights that contribute to reducing defects and achieving higher product quality standards. This improvement aligns with the overarching goal of Zero-Defect Manufacturing (ZDM), ultimately enhancing customer satisfaction and operational efficiency.?
• Real-Time Decision Support: By deploying ML models on the Specular Zero PC within the factory, real-time quality warnings and production recommendations will be provided. This capability empowers operators with actionable insights, enabling them to make informed decisions swiftly and effectively.?
• Continuous Improvement and Adaptability: Post-deployment, continuous monitoring and active learning techniques will ensure that the ML models remain accurate and adaptable to evolving production dynamics. This iterative refinement process aims to sustain high performance and relevance over time, aligning with customer’s commitment to innovation and operational excellence.?

• Alignment with Business Objectives: Throughout the project lifecycle, close collaboration with customers ensures that technical objectives are aligned with overarching business goals. This alignment fosters a strategic approach to leveraging AI and big data, driving tangible business outcomes and reinforcing customer’s competitive position in the automotive industry.?

This concept represents a transformative initiative aimed at harnessing the power of AI and big data to achieve operational excellence and innovation in manufacturing processes. The expected results outlined above underscore the project's potential to redefine production efficiency, product quality, and decision-making capabilities at manufacturing companies, paving the way for sustained growth and competitive advantage in a rapidly evolving market landscape.?

Summarizing the key points?

In today’s article we have seen the potential of Specular Zero technology, summarized in the following points:?

• Specular Zero project by ISR Specular Vision represents a significant advancement in the application of artificial intelligence (AI) for optimizing processes in the production of industrial processes, focused on enhancing aesthetic quality, energy efficiency, and sustainability at TIER 1 and TIER 2 companies.??
• We have explored how AI will be utilized from data preparation to the implementation of advanced models, offering innovative and precise solutions for industry-specific challenges.?
• Specular Zero exemplifies how artificial intelligence can transform traditional industrial processes, improving product quality, optimizing operational efficiency, and promoting sustainability.??
• This advanced approach not only benefits ISR as a company, but also sets new standards for the future industry, driving innovation and excellence at every stage of the production cycle.?