What Is Machine Vision And How Is It Used In Quality Control?

Machine vision is an advanced technology that allows a computer to collect, analyse and interpret visual data. This data can be acquired from cameras, digital images or videos and is used in industrial automation to enhance decision-making. Machine vision enables an automated system to look at anything from a finished product to a code or pattern, and assess it in real time. 

A machine vision system comprises both software and hardware elements. The hardware captures images using light sources, a digital camera, lenses, and possibly associated items such as filters and reflectors. The software then processes and catalogues the acquired images so they can be analysed. 

Machine vision is widely used in quality control because it can measure object dimensions, compare them with a template or sample and detect defects. It improves accuracy and efficiency in production processes, making them safer by reducing human involvement. Machine vision is being increasingly adopted in various industry sectors, including aerospace, automotive, and medical manufacturing.

Quality Control For Manufacturing

Machine vision is proving invaluable in situations where it can perform inspection and guidance tasks far more quickly and accurately than a human being. It can get readings from image acquisition hardware or live cameras and apply them to analytic algorithms. In this way, machines are able to identify and catalogue a range of objects encountered in their environment. 

Quality control (QC) is an essential part of manufacturing, encompassing every process and activity required to ensure that products are up to standard. It demands the rigorous and systematic examination of every aspect of production, from raw materials to the end product. A variety of quality tests are applied at every step of the production process, which help identify process faults and determine the corrective action required to prevent their recurrence. 

When every production process is examined like this, QC ensures that the end products are fit for purpose and comply with all national, international or industry-specific standards. The following QC processes will be wholly or partially carried out, according to the relevant product, client, industry sector or nation’s regulations:

1. Pre-Production Sampling

Initial QC testing is done on incoming raw materials or components to inspect and evaluate them. It’s crucial to identify inconsistencies and defects at this stage before they have a chance to affect final product quality.

2. Technical Inspection

Technical QC testing is performed in a lab, where a deeper and more thorough analysis is carried out on the components or raw materials. 

3. In-Line Inspection

More QC checks are carried out during the manufacturing process. Products are inspected at various stages along the assembly line, so any issues can be spotted and fixed before they escalate. Evaluating the product at regular intervals saves the company’s time, resources and money. It reduces wastage, pinpoints precautionary measures to take for the future and obviates the necessity to alter or re-manufacture the entire product.

4. Out-Line Inspection

Further QC inspections are performed as soon as any product comes off the production line. This step reinforces the in-line inspection process by identifying problems and implementing corrective measures.

5. Final Inspection

This inspection usually takes place when the entire order has been manufactured and approximately 80% of the packing has been completed. This step of QC testing offers inspectors a final chance to prevent any faulty product from leaving the factory, and to remedy any quality issues so they don’t recur.

6. Loading Inspection

An additional precautionary step is to inspect the products during the packaging, labelling and loading processes to ensure these steps are handled safely and responsibly.

QC inspections have traditionally relied on humans to perform these processes, which makes them prone to introducing or overlooking errors. They’re also limited by factors such as labour costs, inflexibility, restricted coverage and delays in production while intricate tests are conducted.

How Machine Vision Benefits Quality Control 

QC processes in manufacturing have been largely automated to eliminate the risks and uncertainties of manual inspections. Newer QC systems with machine vision enable AI to detect and analyse even the smallest imperfections. This provides several major advantages.

• Improved inspection accuracy: Cameras and algorithms are far better than the human eye at spotting anomalies or defects. Their precision ensures stricter compliance with quality standards.

• Improved inspection efficiency: automating the QC process is much faster, especially on repetitive or complex tasks. Machine vision systems significantly reduce inspection times, thus enhancing overall productivity.

• Real-time data collection and analysis: help manufacturers monitor production processes, identify quality trends, and optimise manufacturing operations with informed decisions.

• Flexibility and scalability: machine vision systems adapt easily to changing production needs. They can quickly be reprogrammed for varying inspection requirements and integrated without significant disruption into existing QC processes.

There’s a fast-growing market for machine vision in QC in industries like pharmaceuticals, electronics, automotive, food and beverages. Their more advanced inspection techniques and extreme precision benefit the increasingly diverse and complex range of manufactured products demanded by our high-tech world. 

There’s also a higher expectation for safety and product quality, as defective products can cause customer dissatisfaction, recalls and potential safety hazards. Machine vision enables early identification and elimination of defects, so only safe and high-quality products reach the market.

Why Opt Into Machine Vision For Quality Control?

Machine vision is revolutionising automated industrial manufacturing. Companies are leveraging its efficient, accurate QC and real-time data analysis to enhance product quality and comply with regulatory requirements. With advancements in Industry 4.0 technology and expanding market opportunities, machine vision QC processes are likely to grow significantly in the future years. With quality standards and regulatory requirements across industries becoming increasingly stringent, machine vision will help to reduce the risk of non-compliance penalties.

Quality control is vital in the manufacturing industry because it has such a direct impact on so many aspects of the production process. Machine vision QC enhances the capacities of QC systems with better performance, lower maintenance costs and increased customer satisfaction. Companies that utilise these systems enhance their brand reputation for product reliability, thereby earning customer trust and loyalty.