No defect material to the customer! SMASHTM / Quality … in no defect to your final customer! 6...
Transcript of No defect material to the customer! SMASHTM / Quality … in no defect to your final customer! 6...
1
RRRR No defect material
to the customer!
SMASHTM / Quality-Reviewer
2
I will not discuss …
- how to detect a defect …. - which camera is the best to use …. - which light configuration is recommended …. - algorithms for best classification results ….
- I will not talk about granted basics !
I will not discuss about:
3
I want to speak about …
I want to speak about the question: - What to do after having found defects ? - How to avoid shipping the defects to customer ? - How to get most value out of inspection data ?
4
Beyond Inspection
Tools to get most value out of inspection data: - Reviewer - Data Mining and Reporting - Slit Optimization - Quality Reviewer
5
The Web Coating Story
The Web Coating Story is about Outstanding performance in defect detection! Outstanding performance in data handling! Implementation of the inspection data in the production workflow! Making the quality decission process fast and reliable!
Results in no defect to your final customer!
6
Jumbo Jumbo Jumbo
Web Product Process We support the complete production chain
Coating line
Insp
ectio
n
Slitt
ing
Prev
iew
Def
ect T
rend
A
larm
ing
Sort
ing
out
Dau
ghte
rRol
l B
lock
ing
Qua
lity
deci
ssio
n
Transfer defect data from Jumbo roll to customer daughter roll
Storage Buffer for Jumbos Slitter
Roll1 Roll2 Roll3 Roll4
Transportation to the customer
7
Jumbo
Inspection
While the Jumbo Roll will be produced the SMASH System detect defects !
Insp
ectio
n D
efec
t Tre
nd
Ala
rmin
g
Coating line
8
Inspection
The Production Process The speed is too high for the human eyes to see defects The Jumbo roll runs for a certain time The Jumbo roll is more than thousand meters or even several
kilometers long Inside this length can be critical defect: A small fruitfly !!
Don‘t let it become Your customer‘s fruit fly!!
9
Inspection
So lets try to find Your fruit fly in the process!
10
Review of Inspection
All defects will be displayed in the RealTime Viewer
11
Review of Inspection
Also Your fruitfly!
12
Inspection
The fruit fly is inside the database, stored with hundreds of other defects. Some of them are relevant, some are not relevant.
13
Quality Review
We are still before slitting! The daughter roll with the fruit fly needs to be identified!
14
Jumbo Jumbo
Quality Review Now the Jumbo roll is finished and stored.
Slitt
ing
Prev
iew
Dau
ghte
rRol
l B
lock
ing
Qua
lity
deci
ssio
n
Transfer defect data from Jumbo roll to customer daughter roll
Storage Buffer for Jumbos
15
Quality Review
The human quality inspector now reviews the Jumbo roll
Indentifying all critical defects
Preventing shipment of defects to customer
Informing the operator at the Slitter
Document the internal quality process
Order spare rolls from the warehouse
Release of quality for shipment
16
Quality Review
This will be fully supported with SMASH Load the Jumbo roll
Load the cutting schema (Roll Cut Layout)
Consider material stretch in Downweb and Crossweb
Reviewing the defects
Blocking of the defective daughter roll
Don
e in
5 m
inut
es
17
Quality Review
Load your Jumbo roll
18
Load the cutting schema Load exsting cutting schema
Create new cutting schema
No limitations in creation of cutting schema.
Consider the stretch in MD and CD in % or mm
Quality Review
19
Apply your cutting schema
Stretch Coefficient
Cross Cuts
Length Cuts
Quality Review
20
Now the cutting schema is applied to the Jumbo roll!
Cutting schema
Quality Review
21
Now we have to find the fruit fly! Quick browsing through the defect images with the Defect Viewer!
Quality Review
22
You found the fruit fly! By pressing the button the daughter roll is blocked!
Quality Review
23
There is much more the Defect Viewer can do for You! Indicating if the defect is near a cutting position => take out both rolls
Hiding defects of blocked roll
Showing you the sourounding of the defect by 1x1meter
Quality Review
24
Indentification whether the defect is near a cutting position!
Defect position near cutting edge. Check neighbour roll as well!
Quality Review
25
Showing you the sourounding of the defect by 1x1meter!
Gives you additional information
Quality Review
26
Hiding defects of blocked rolls!
Reduce time and effort in reviewing defect data
Quality Review
27
Sorting Out We support the complete production chain
Sort
ing
out
Transfer defect data from Jumbo roll to customer daughter roll
Slitter
Roll1 Roll2 Roll3 Roll4
Transportation to the customer
28
All defects are verified! The report of the blocked roll will be handed over to the operator at the
slitter.
Sorting out
29
Sorting Out
OK
OK
OK
OK
OK
Transportation to Customer
Transfer defect data from Jumbo roll to customer daughter roll
The fruit fly is sorted out!
30
All decissions are documented and traceable
The Quality Reviewer Order oriented quality evaluation
Quality view of Multiple Jumbo Rolls belonging to one order
Verifying decissions on one finger tip
31
Quality Insurance and Data Handling
Order Number
Blocked Roll
Our fruitfly
32
Why SMASH?
No relevant defect reaches your customer!
You avoid complaints and unhappy customers
You fulfill the demands of your customer
Quick and effective quality evaluation
Argumentation and documentation of your internal quality process towards your customers
Prove your quality by giving reports to customer
Pass better the customer audits
33
Requirements
SMASH System in the production line
Reviewer
Software “Quality Evaluation"
PC and Network to Inspection System Database
Trained Operator
34
Configuration – single installation
Your PC
35
Configuration with access to several single lines
Your PC
36
Configuration with access to several lines with common database
Your PC
inspection database
37 37
ISRA: Facts and Figures
Established :
Legal Form :
Number of Employees :
Sales 2010/2011 :
R&D Investment :
1985
AG, public company
490
75 Mio. €
11 Mio. €
46% 56%49%
39%19%
52% 11% 7% 8%
33%-15%
12%16%
20
40
60
80
100
120
97/98 98/99 99/00 00/01 01/02 02/03 03/04 04/05 05/06 06/07 07/08* 08/09* 09/10* 10/11*
Revenues in mil €
Datenreihen2
38 38
Subsidiaries: Germany: - Darmstadt (Headquarters), - Aachen, - Berlin, - Herten, - Karlsruhe, - Mainz, - Bielefeld USA - Atlanta, - Bloomfield Hills China - Shanghai, - Tianjin Korea - Seoul Japan - Tokyo Taiwan - Taoyuan India - Mumbai, - Calcutta Brazil - Sao Paulo Turkey - Istanbul
Herten, GER
Shanghai, CN
Atlanta, USA
Worldwide Organization Close to the Customer
Aachen, GER
UK - Hampshire, - London Finland - Helsinki Italy - Rovereto Spain - Barcelona Ruddia - Moscow
Bloomfield Hills, USA
Production : Germany: - Darmstadt, - Herten, USA - Atlanta, China - Shanghai, Turkey - Istanbul
Asia/ ROW
Americas
Europe
Revenue in Regions
38
39
Thanks for your attention!
Questions?