Realized in collaboration with Keyence (Thailand)! Automation of appearance inspection, a positive-forward way for cost reduction [YN2-TECH × KEYENCE interview]

29/05/2020

Ryota Nakamura

Managing Director

In Thai manufacturing industry, demand from customers for quality is increasing. In this article, we take up on the appearance inspection of products, which is an important factor for quality. We present you an interview with Yoshihiro Sumi, a Production Line Manager of Keyence (Thailand), a leading company of FA, and Ryota Nakamura, the Managing Director of "YN2-TECK", the company of product development / production technology by DPE.

YN2-TECH KEYENCE

―GUEST―
YOSHIHIRO SUMI, KEYENCE (THAILAND) CO., LTD. The person in charge of the Image Processing Department. After working in Japan for sales and Sales Promotion Group, he was assigned to Thailand in August 2017.

Development of image inspection machine / Encounter with Mr. Sumi of Keyence

Nakamura: It was the development of an image inspection equipment that we were consulted by a customer that had led YN2-TECH and KEYENCE to collaborate. That was a very difficult and short-term development project.

Sumi: Since that was my first time encountering such project, I was worried if I could really solve it.

Nakamura: The challenge was how to perform analysis using images in the production line. Even if an image can be photographed by a camera, how can it be analyzed? It was very difficult to develop the analysis part.

Sumi: When I actually tested it using Keyence's image processing algorithms, I was confident to some extent that the problems of the analysis part could be solved.

appearance inspection equipment

- The key point of an appearance inspection equipment is “picture making”

Nakamura: Technical capacity of Keyence is extremely excellent. I would like to ask you about the important points in appearance inspection technology.

Sumi: The success of appearance inspection using image processing is determined by the picture making process. Keyence is focusing on how to make pictures that are easy for software to process.

YN2-TECH KEYENCE

- Cost reduction by "quantification" of appearance inspection

Nakamura: The main subject of today is the cost reduction by automating the appearance inspection. Please tell us about.

Sumi: The greatest cost reduction effect is "replacement of visual inspection". Entrust most of human tactics inspection to be automated by camera. Then, there are many cases where one person can do the work that required five people.

Nakamura: Out of Mr. Sumi’s suggestion, the keyword that impressed me was "quantification of appearance inspection." In the appearance inspection by humans, even if there is a reference sample for inspection standard, there will be a difference if the inspector is different between the day shift and the night shift. In worst case, it will make a difference depending on the mood of each person. Under such circumstances, I thought that “quantification” is an important keyword.

Sumi: The boundary between approved and defect product in appearance inspection is very fuzzy to start with. For image processing, you can set a certain number, defect if it is exceeded, approved if it falls below. Since it is judged mechanically by numbers, there is basically no oversight.

- Trust and expectation for future orders enhanced by automation of appearance inspection

Nakamura: Further questions in cost reduction through automation. I think that there is other reduction effect than personnel expenses. How about it?

Sumi: In the case that our customers were pleased, once they put out a defect product, it will cost a huge amount of money to recall it. Millions of Baht will be lost. The risk of loss due to defect products can be minimized by automation.

Nakamura: Considering that such recall may involve outside of Thailand, the cost may be unimaginable. For manufacturers not only in Thailand but in Southeast Asia, appearance inspection equipment may be a facility that stabilizes corporate profits. In other words, it's not just a reduction in inspection personnel, but a positive-forward facility that produces long-term profits.

Sumi: In addition to the risk hedging effect, the installation of the equipment achieves trust from the users of customers, which may lead to future orders.

Nakamura: While the market is shrinking due to the effects of corona, it is necessary to introduce an appearance inspection that allows you to go forward while protecting yourself.

■ If you are interested in YN2-TECH's 3D solution & TEXTILE technology, 3D printer, appearance inspection equipment, and or 3D scanner, please contact us using the form below.

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