"Designing Vision Systems for Human Operators and Workflows," a Presentation from 8tree

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www.8-tree.com Designing Vision Systems for Human Operators & Shop Floor Workflows

Transcript of "Designing Vision Systems for Human Operators and Workflows," a Presentation from 8tree

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Designing Vision Systems for

Human Operators & Shop Floor Workflows

A Case Study:

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Lisbon Hangar Capacity: 3 WB, 5 NB Hangar Area: 26,380 m² Total Building Area: 71,200m²

Rio de Janeiro Hangar Capacity: 4 WB Hangar Area: 14,500 m² Total Building Area: 180,000m²

Porto Alegre Hangar Capacity: 1 WB, 5 NB Hangar Area: 12,500 m² Total Building Area: 55,000m²

• Leading global provider of heavy-check Maintenance Repair and Overhaul (MRO)

services

• Operations in Brazil and Portugal

About TAP-M&E

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The Dent-mapping Problem

Hail Damage Damage due to ground equipment Lightning strike (Image Source: Boeing)

The Challenge The Ideal Solution

Achieve reliable, accurate and objective - Dent-mapping & assessment - Corrosion Blend-out

Real-time. Boosts inspection efficiency

Reliable & Consistently Accurate

Comprehends industry-mandated* tolerances

Instant Answers…not just data

Handheld-portable. Field-friendly. Zero Learning Curve

No Surface Preparation needed

(Image Source: Wikipedia)

* Structural Repair Manual (SRM) details tolerances for Aviation Maintenance industry

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What operators demand What operators must tolerate

Ease of use Difficult learning curve

Accuracy Complex tools & menus

Consistency Long interpretation & reporting time

Reliability Subjectivity & Human-error

Operator Experience Today

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“Traditional dent-checking methods are very time consuming

and frustrating”

Valter Fernandes

EVP, Operations

TAP-Maintenance & Engineering

TAP-M&E: The Problem Statement

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Traditional Mapping Methods

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Traditional Mapping Workflow

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Typical industry format

• Minimal identification data

• Basic numeric measurement values

• Relies on manual entry of location information

• Text-only, unless operator attaches a photograph /

manual drawing of affected area

Dent Reports: Traditional Methods

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Tool introduction inside TAP (Oct 2015)

• User training – minimal; intuitive 1-button operation

Integrating the system inside TAP’s workflow

• First-phase = Dent-Mapping

• Next-phase = Corrosion Blend-out, Scratch & Gouge Blend-out

Acceptance by technicians – easy-to-use tool

Implementing @ TAP-M&E

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• Point-and-shoot

• Never look away – eyes always on task!

– Go/No-Go Digital Mapping

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• Dent-Reporting Tool – Image-based reporting format with traceable measurement values

• Measurement values extracted directly from SRM-compliant dentCHECK results

Dent Reports:

Information Rich Reporting

A / Y (or W / D)

Deepest point x-section

Distance to frame & stringer

Detailed log (operator ID, time-stamp, job #)

Color-coded annotation

Audit-ready digital reporting

Customizable reports

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Extremely rich and detailed results – visual and SRM-compliant numeric answers

Handheld Portable design – ideal for the shop floor – no wires, no PC, no power

supply

dentCHECK Dent Reporting Tool (DRT) – “brings the airplane into the office”

All measurement results are digitally captured for ease of record-keeping and

sharing with OEMs and Operators

Zero-learning curve – almost no training required

Compliant with and recognized by OEM standards – Approved by Airbus

Benefits Realized: @ TAP Workflow benefits

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dentCHECK reduces Mapping AND Reporting time by >90%

Step Task Time taken (Traditional Methods)

Time taken

( )

1 Setup per dent 5 min 1 min

2 Operator maps a dent on aircraft* 10 min 30 seconds

3 Multiple operators repeat measurements on same dent to verify and reach consensus

10 min 30 seconds

4 Create a dent-mapping report for each dent* 10 min 1 min

Total 35 min 3 min

* In an SRM-compliant fashion

Benefits Realized: @ TAP Time and Efficiency Gains

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dentCHECK saves 14 days of time and labor with every day of use

Return on Investment (ROI) period ~2 months

Benchmarking Efficiency & ROI

Man-Hours

Dent Mapping & Reporting

Traditional Methods With

1

2 Dents

30 Dents

8

(1-workday or 1-shift)

16 Dents

240 Dents

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“dentCHECK isn’t simply an enhancement to our dent-mapping

processes…

…it’s a huge leap in efficiency!”

Valter Fernandes

EVP, Operations

TAP-Maintenance & Engineering

Empowering Airlines/MROs

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Vision System Design Philosophy

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dentCHECK application, product and workflow

• Everything has to support the idea of ease of use

• UX and UI design

• Response time after pushing the button ideally < 1 s

• “Look Ma, no wires!” – No external cables, computers, monitors or

keyboard

• Mobile, handheld, lightweight

• Mechanical Robustness and ‘drop-protected’

• Long-lasting calibration

• All complexity should be hidden inside the box

• Minimal training requirements

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Requirements in developing a vision based product for mobile, handheld and shop floor use

Inside the Box:

• A USB3 camera with IMX174 Sensor running at

160 Hz

• A Intel NUC computer with i5 processor

• A Texas Instruments DLP projector

• Powered by 98Wh battery for 4 hours operation

• Scan time 0.1 s

• Evaluation time 2-5 s

• Augmented Reality (AR) projection of results

onto the inspected part

• 2 button operation

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How did dentCHECK address these challenges?

Intel NUC computer

DLP projector

IMX 174 Sensor camera

Some of the guidelines below are inspired by early

Apple consumer products. At 8tree, we are convinced

that this design philosophy is very valuable in industrial

products too.

DISCOVERABILITY: The ability to look at the system

and immediately discover all the possible actions

FEEDBACK: Allow a person to know what happened

after an action was taken

RECOVERY: Errors happen. Recovery dictates it should

be as easy or easier to undo than to do

CONSISTENCY: Most technology users have more

than one device, yet the operations of the different

devices often clash

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“Don't bend to technology.

Bend technology to your

needs” - Jason Pontin

MIT Technology Review

Design Philosophy in dentCHECK

A key function in dentCHECK is to find out what the undamaged surface would look like

• We call that the Virtual CAD model

• Knowing what is right and what is wrong without further input

• By fitting a mathematical surface to the 3D scan data we can measure and display the size & depth of

a dent

• This works on planar and simple curved surfaces

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How does dentCHECK work?

Fitted Surface

8tree products can produce and store meaningful data about their own state…as

well as…

…about the objects being inspected

…provide results through easy to use interfaces for

cloud services or mass storage

…allow insight through big data applications

e.g. predictive maintenance

Industry 4.0 and IoT

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dentCHECK – anticipating user needs

Higher image frequency and matching bandwidth on camera-computer interface

Less power consumption from cameras, projectors, computers

Increased processing power

Support of GPU computing

What 8tree would like to see from the vision supply-chain to enable our future roadmap

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Ease-of-Use

Intuitive

Portable & Self-

contained

Flexible High-speed

Accurate & Consistent

Zero Learning Curve 1-button operation Tablet/smartphone control No surface preparation needed

Traceable to National Standards

Lightweight No cables or monitor

No external CPU

Actionable Results <2 sec Efficiency boost >10x Real-time feedback

Barcode Configuration

Ease-of-Use that Empowers the Operator

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Don’t Let Dents Compromise Safety Use the Gold Standard

Who’s using ?

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