Fast Process Improvements Through Prototyping and Vision-Based Inspection
From initial process analysis to automated image-based inspection, IMSTec developed an innovative solution that transforms subjective quality checks into objective, data-driven process .
Digital Particle Inspection for Enhanced Process Reliability in Polymer Processing
Initial Situation:
The customer aimed to improve an existing manual inspection process in terms of reproducibility, transparency, and data evaluation. The previous quality control procedure relied on visual inspection of samples, provided only limited documentation capabilities, and required significant manual effort.
The project's objective was to develop an objective inspection method capable of automatically detecting, quantifying, and digitally documenting anomalies. At the same time, the solution needed to be implemented quickly, improve the existing workflow, and provide a foundation for future automation initiatives.
Challenge:
As part of a Process Failure Mode and Effects Analysis (pFMEA), the existing inspection workflow was jointly reviewed and assessed. The goal was to increase the reliability and consistency of quality inspections while establishing an objective data basis for process monitoring and continuous improvement.
Solution:
IMSTec first implemented a practical short-term solution to enhance the existing manual inspection process. Using additive manufacturing, a custom-designed lid attachment for the sample containers was developed, allowing the inspection film to be positioned securely and reproducibly. In addition, the film material itself was optimized to prevent wrinkles and eliminate measurement deviations caused by material distortion.
Building on these findings, IMSTec developed a prototype inspection system for automated digital particle analysis. Utilizing intelligent machine vision technology, inspection films are automatically captured, and image data is analyzed through advanced software algorithms.
By combining and evaluating multiple image recordings, particles can be reliably detected, counted, and characterized. Key parameters, including particle diameter and distribution, are automatically determined and documented. The collected data is provided in a structured Excel-based reporting format, giving the customer a transparent, reproducible, and data-driven foundation for quality assessment, process monitoring, and future process optimization.
Key Results and Customer Benefits
Improved reproducibility and consistency of quality control processes
Digitale Dokumentation der Prüfergebnisse
Objective detection and measurement of particle count and particle size
Fast and cost-effective enhancement of existing inspection workflows
Transparent, data-driven basis for quality analysis, process monitoring and regulatory documentation
Foundation for future automation and advanced quality control systems
Mehrwert auf einen Blick
Schnelle Lösungen durch pFMEA und Prototyping
- Durch die strukturierte Analyse im Rahmen der pFMEA konnten potenzielle Fehlerquellen frühzeitig identifiziert und konkrete Verbesserungsmaßnahmen direkt abgeleitet werden. Statt langwieriger Entwicklungszyklen erhielt der Kunde innerhalb kurzer Zeit erste funktionsfähige Lösungsansätze zur Optimierung seines Prüfprozesses.
Entwicklung mit Blick auf den gesamten Prozess
- Die Lösung beschränkte sich nicht auf die Behebung eines einzelnen Problems. IMSTec betrachtete den gesamten Prüfablauf und entwickelte eine zukunftssichere Lösung, die den Weg von der manuellen Qualitätskontrolle hin zur datenbasierten Prozessüberwachung unterstützt.
Alle Kompetenzen aus einer Hand
- Von der Analyse über Design bis hin zu Prototypenbau, Bildverarbeitung und Softwareentwicklung wurden sämtliche Arbeitsschritte inhouse umgesetzt. Dank der engen Zusammenarbeit verschiedener Fachbereiche konnten Ideen schnell validiert und Optimierungen ohne Schnittstellenverluste umgesetzt werden.