Experience example

Vision Systems Improving Quality & Efficiency

"Vision, the ability to plan for the future with imagination or wisdom" - Oxford English Dictionary

Industry
Manufacturing

Sector
Paint

Project

  • The client is an international manufacturer and marketer of premium branded paints and industrial coatings.
  • The client had identified two production issues at their solvent-based paint manufacturing facility:
    • Paint cans were mechanically orientated via a time consuming manually set-up system.
    • Laser batch code etching on the cans was checked physically.
  • The client identified that a vision system could be utilised to:
    • Automatically check batch and code conformity with their ERP system.
    • Check the uniform orientation of the paint can handle prior to the palletiser to prevent spillage or misalignment on the pallet.
  • The client engaged Cromarty for assistance with the deployment of the vision system.

Solution

The solution involved to distinct parts:

  • The implementation of a vision system to read the batch number on a can. Then checking the image matched with the database and storing the image in a network file location.
  • Use shape search to mark the orientation of a can to a known position and then rotate it so that handles aligned for robot stacking on a pallet to prevent misalignment.

Cromarty's scope included:

  • Development of the functional description
  • Design of the system
  • Installation and commissioning
  • Operator/maintenance personnel training for use and maintenance of the system
  • Ongoing support

The system had to be designed, installed and commissioned with minimal downtime as to not interfere with production.

Outcome

The solution was extremely cost effective as only two vision system controllers were used but with the deployment of multiple cameras 6 production lines could be covered. The removal of manually checking the laser etching of batch codes eliminated cans being produced with no batch code.

The system also greatly reduced the time and effort required between products changes for can re-orientation resulting in less time orientating the can resulting in less palletising errors. The solution also included the training of maintenance staff to add new products to the system without the need for specialist engineering support.

The client realised less downtime, more production and increased efficiency.

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