Others – Flexible Automation System Sdn Bhd.

2D Code Vision Inspection System

webadmin — Mon, 08 May 2023 09:50:33 +0000

2D Code Vision Inspection System

Industry: Consumer Products
Brands: Cognex
Case Number: PH-0021
Solution: Vision Inspection

Problem Statement

Consumer Products Co would like all machines to come with a 2D reader to inspect the presence of the 2D code and whether the right packaging is loaded into the machine. This is very critical, otherwise, the whole lot will be rejected.

Solution

To address the issue, we have provided the customer with a high resolution camera to inspect the presence of the 2D code as well as detect the model code of each packaging and right packaging loaded.

Customer’s Feedback

Cognex ID reader’s overall performance stability and the accuracy rate in reading 2D codes satisfied the customer’s requirements. The customer was able to efficiently eliminate defective packaging there by reducing overall reject rate.

Patlite Wireless Data Acquisition

webadmin — Mon, 08 May 2023 09:16:10 +0000

Solutions

Patlite Wireless Data Acquisition

SSCN Number : SSCN-0008
Project Number : FASMY-1802-006
Solution : Patlite Wireless Data Acquisition
Industries : Manufacturing (Others)

Problem Statement

– No actual information about machine status on the production floor.
– Management only could base on a manual recording to estimate the production output and planning. Require lots of time and resource to gather data and compilation.
– Planning and actual always have variance.

Solution

– Install Patlite Wireless signal tower light on each machine.
– Gather all the machine status by using Mitsubishi PLC via wireless transmission.
– FAS customization software for visualization and analysis.

Results

– No messy wiring is required from machines.
– Real time status can be visualized and not required manual recording.
– Machine OEE can determine and plan to continuous improvement.
– Increase production productivity.

RFID and Vision Camera for Traceability System

webadmin — Thu, 13 Apr 2023 00:57:22 +0000

Solutions

RFID and Vision Camera for Traceability System

SSCN Number : SSCN-0011
Project Number : FASKL-1905-400
Solution : Traceability Vision + RFID
Industries : Graphite Electrodes

Problem Statement

– Operator manual log in the product ID after the laser mark.

– The start inspection time and data and end time must able to log in to the server for traceability purpose.

Solutions

Vision Camera:

– Using the 12 Mp Smart Camera to detect the OCR code and send the read data to the PLC for logging.

RFID:

– All the electrode are fixed with the RFID tag from the input conveyor.

– The first reader read the ID and start test time when the electrode load to test station.

– The second reader read the data after the test process.

– Both readers send data to PLC for test result confirmation.

Traceability System With Data Logging

webadmin — Thu, 13 Apr 2023 00:54:44 +0000

Solutions

Traceability System With Data Logging

SSCN Number : SSCN-0010
Project Number : FASKL-1807-260
Solution : OCR traceability system
Industries : Graphite Electrodes

Problem Statement

– Operator manual log in the product ID

– No traceability function

Solutions

– Using the 5Mp Smart Camera to detect the Product ID.

– The high brightness bar light will use to handle the long working distance.

Results

– All product’s ID able to read and send to do comparison with server data.

Wireless Monitoring for Production Machine Status

webadmin — Tue, 04 Apr 2023 07:32:51 +0000

Solutions

Wireless Monitoring for Production Machine Status

SSCN Number : SSCN-0001
Project Number : FASMY-1802-006
Solution : Patlite Wireless Data Acquisition
Industries : Metal and Machine Tools

Problem Statement

– No information about machine status on the production floor.
– All planning is base on manual recording data.
– Required additional manpower for the recording and reading is a variance from Actual.
– The mechanical machine does not have any controller for digitalization.

Solutions

– Install Patlite Wireless signal tower light on each machine.
– Machine status will transmit via tower light and consolidate at Mitsubishi PLC.
– All the data will be visualized by using FAS customization software.
– Real-time production performance can be determined.

Results

– Reduce manpower for all the manual recording and auto-generation of production report.
– Increase productivity and OEE.
– No messy wiring is required.

Deep Learning-based Approach to OCR

webadmin — Fri, 24 Mar 2023 01:00:10 +0000

Solutions

Deep Learning-based Approach to OCR

SSCN Number : SSCN-0029
Project Number : FASKL_VKL2011127
Industry : Others
Solution : Machine Vision System/AIDC
Brands : Cognex

Problem Statement

The graphite electrode is labeled with a unique code for monitoring and tracking purpose. This unique code contains alphanumeric character that is stamped onto a graphite electrode. Poorly stamped characters, confusing background and unwanted noise make it difficult for a machine vision system with traditional rules-based approach to recognize the characters.

Solutions

With In-Sight ViDi, a powerful deep learning software platform, the In-Sight D900 vision system is able to read characters under challenging situations such as noisy backgrounds and poorly stamped characters. In the training phase, images under different conditions were collected and labeled for training and validation purposes. During training & validation phase, re-labelling of the incorrect characters or missed characters is done until the software’s model is able to correctly identifies all characters. When deployed, the In-Sight ViDi Read tool operates on input images and produces results based on the validated training data.

Benefits

Good reading rate for low quality ID stamped characters. With deep learning-based OCR, reading rate improves by at least 20% as compared to traditional rules-based algorithm.

Facility Monitoring for Watch Manufacturer

webadmin — Thu, 23 Mar 2023 03:44:54 +0000

Solutions

Facility Monitoring for Watch Manufacturer

Industry: Consumer Products
Brands: Mitsubishi
Case Number: PH-0022
Solution: Facilities Monitoring

Problem Statement

A Japan renowned watch manufacturer opened its new plant to manufacture watches in Philippines. The facility started with manual monitoring of power usage/efficiency, water treatment status and compressor alarms. These have resulted in downtime both on tracing alarms and problems of the facility system. As well as having a more reliability of power usage, efficiency and distribution.

Solution

The solution provides monitoring & control over:

Power usage, efficiency and distribution monitoring
Water Treatment and Waste Water Treatment status monitoring
Compressor alarm monitoring

Benefits:

Able to establish power saving solutions/activities.
Reduce downtime in tracing problems for the WT and WWT.
Reduce downtime on manpower on checking compressor alarms.
Able to collect data and use for data and problem analysis.

Energy and Condition Monitoring for Undercarriage Manufacturer

webadmin — Wed, 22 Mar 2023 08:33:19 +0000

Solutions

Energy and Condition Monitoring for Undercarriage Manufacturer

Industry: Heavy Equipment
Case Number:FASID 2004-002
Solution: Energy and Condition Monitoring of Air compressors

Problem Statement

Machine operation was interrupted when pressure drop in the compressed air system because of compressor breakdown or sudden stoppages.
Customer don’t know the performance of each compressor
Energy consumption data of each compressors are recorded manually on paper from conventional electricity meter.
How much actual air volume is produced by each compressor is unknown.

Solutions

Monitor electricity data on each compressor , more than 10 compressors.
Install Ultrasonic Flow meter on each output of compressor room to measure air parameter such as instant flow rate, accumulated air volume, temperature, pressure, and direction.
Read status of compressor from its control unit by Modbus RTU serial communication.
Monitor and record all of the data and status into SCADA dashboard by Mc Works 64 Mitsubishi

Benefits

A dashboard with a clear overview of the entire factory compressor layout, with status and flow data for each compressor. This helps maintenance staff to easily identify and monitor status of compressor ensuring quick response and correct action to take.
Rich data sets collected for trend and data analysis. Data such as line pressure, final pressure, maintenance hour, temperature and electric current value are some of the parameters used for analyses of the compressor health .
With compressor efficiencies and running hours as guide line, user is able to prioritize which compressor to run to optimize the efficiencies.
The systems is able to automatically load or unload the compressor based on priority list via remote control following the setting of pressure range/span.