Vision System for Parts Identification

In the parts manufacturing industry, a single misidentified part can have far-reaching consequences at a steep cost to both the manufacturer and its customers.

In response, Akeratos helped create an automated vision system that drastically reduces the potential for human error. It uses a camera and computer software to inspect and identify each part.

Parts are programmed into the vision system to identify key features that make each product unique. Programming begins by capturing a clear picture of each part, taking into consideration the best possible orientation and lighting conditions.

Once the picture is taken, the software is programmed to recognize unique features that allow the differentiation of part configurations. These unique features can include area widths, hole locations, hole sizes, or other features.

After the program is written, parts are tested using the software to determine whether the part’s unique features match what the software considers a good part. The operator receives a “GOOD” or “BAD” indication from the machine, quickly telling them whether the part is the correct configuration.

During an assessment, Trinity Precision’s Planning and Quality teams identified part inspection as a process in need of overhaul. They realized some parts they manufactured for different customers could look similar or, in some cases, nearly identical.

The existing part inspection process required a dedicated inspector to visually evaluate each part using hand-held equipment. That process carried a high risk of error. Key features could be misidentified or inaccurately measured.

After further investigation, Trinity Precision determined that part misidentification is one of the most significant quality drivers in their industry:

• Average monetary cost of $3,500 per occurrence, depending on where in the process the error gets caught
• Lost production time for the manufacturer and the customer
• Erosion of trust and reputation
• Safety — by far, the most serious cost

Trinity Precision first partnered with Rye Design LLC, then with Akeratos LLC, to create an automated part-identification solution to reduce human error.