Over the last five years, deploying machine vision on the factory floor has become extremely easy. The big six machine vision suppliers have made their software easy to learn, easy to use, and can perform tasks better and faster than ever before. Just ask them.
So why does anyone need to use a Machine Vision System Integrator?
Experience
Most system integrators have more than a decade of experience under their belt. If the company itself does not, they employ people that have the depth of knowledge to guide you in selecting the right system for your needs.
Even though vision system manufacturers have made their software more user-friendly, there are times when it is just not that easy to get the results you want. Integrators spend a tremendous amount of time learning the little nuances of the vision software. Integrators are not infallible, though. However, when they run into trouble, they know who to contact within the vendor’s hierarchy to get the quickest solution.
Beyond basic component selection and software programming, integrators know how to implement the vision system within the broader context of the application. They can determine the best location for the components, and if any other equipment is needed (i.e., lighting tunnels/hoods, etc.) to make the vision system more robust. Downstream process locations can be calculated based on the vision system’s capabilities without a lot of trial-and-error movements. They can even tie the vision system within the plantwide control system for data collection and control.
At Global Controls, Inc. (GCI), our vision experts have over twenty years of experience in selecting, programming, and deploying machine vision systems. When joining GCI, new engineers are first trained in our lab to master the basics before tasking them with any field requests.
Process
Good integrators use their experience to solve your machine vision needs. Outstanding ones insist on using a defined process to ensure success. The procedure may vary between integrators, but they should all have similar structures – evaluation and proposal, design, assemble, test, and install. The benefit of this process is risk mitigation. Each step within the process should have checks and balances to prevent a project from running away in both time and costs.
Evaluation
Each project should start with an evaluation of the technical feasibility; by imaging the subject parts to be inspected. Adding a review of the installation site and even performing an engineering study on site will make the evaluation even better. Should the project be viable, an integrator will detail the project requirements, goals, deliverables, and costs of each step of the process within a proposal.
Design
Most of the time, design work must be done just to determine the feasibility of the project. But, after a purchase order is let, the integrator will review each step of the inspection process and select the best imager, lighting, and mounting that will perform and still meet the budget of the project.
Assemble and Test
Before bringing any material to your facility, integrators will typically assemble and test the system to ensure it is flawlessly working based on the requirements agreed to during the evaluation phase. System testing could include building small electrical panels, lighting or environmental tunnels, mounting brackets, reject stations, etc.
The integrator should insist on requiring you to witness the testing during a Factory Acceptance Test (FAT), which includes reviewing the test procedure and the acceptance criteria.
Sometimes it is not feasible to perform testing at the integrator before installation on site because your process may be too complex to duplicate. Therefore, the integrator should offer a Site Acceptance Test (SAT) to make sure the system operates to your satisfaction.
Installation
Beyond designing and building an inspection system per your specifications, an integrator should provide installation services, as well, because they are best equipped to ensure the system is installed correctly and works long-term.
The integrator should offer on-site, in-person user and supervisor training as part of the testing and installation of the machine vision system. The training should include documentation that allows you to operate and service the system after the integrator has finished.
Leading integrators offer post-install service and support also. They may offer service contracts as part of the proposal to cover training of new personnel, periodic preventative maintenance, or minor software adjustments. They could even work with you in the future should your budget not allow for it upfront.
At GCI, we add three signatory reviews to these basic steps.
The first occurs after placing your purchase order. We insist on holding a kickoff meeting with all the stakeholders of the project to make sure all concerns and issues are resolved before continuing.
The result of this meeting is a comprehensive statement of work, including the requirements and expectations of all parties, a list of success factors and mitigation steps, and a project timeline. We insist on the customer signing this document before moving forward.
The second signatory review is the Control Narrative. We produce a detailed narrative of how the system will work, a list of input and output signals, and fault recovery steps. If there is a human-machine interface, the narrative provides a snapshot of the critical items or screens to that interface. We require the customer to sign this document before moving forward.
The third signatory review is for testing, whether that be FAT, SAT, or both. This document details exactly how we will perform the test(s), the material needed for the testing, the length of time for the test, and the pass/fail criteria. Typically, this review is accomplished during the assembly phase of the project but must be signed by the customer prior to starting any tests.
Conclusions
Using a system integrator will benefit the user by utilizing their experience and processes to ensure the best machine vision inspection system. Integrators are not going to be inexpensive compared to attempting to accomplishing the project on your own. But it allows your personnel to concentrate on their strengths – producing the best possible product you manufacture.