Whether looking to update an existing process or implement something brand new, process design is a critical aspect to any project. One of the tools that provides lots of potential for improvements in product quality is automation.
While Commissioning, Qualification, and Validation (CQV) times of an automated system may take longer than other more manually intensive processes, when done right, automation can provide key improvements when looking to upgrade select processes within the manufacturing environment. These can include but are not limited to:
- Reducing process downtime
- Reducing manual intervention and errors
- Real-time detection and recording of deviations
- Improving the consistency and control of a system
While these benefits are all important, the ability to improve the consistency and control of a system may be the greatest. Making use of different sensors, cameras, and/or programming, readings can be taken and recorded from a specific batch with no manual intervention. This allows for a greater degree of control and consistency when designing a process. After calibration and optimization has occurred, an automated system can monitor key parameters within the process to detect, record, and even prevent deviations from normal procedures in real time. If a parameter value is to high or low, the process can even stop itself until the issue is corrected thereby limiting its impact to the overall product. Deviations from normal procedure can result in problems with product quality causing major losses and problems for everyone involved. In the automotive industry, Faurecia, has turned to automation, in the form of a deep learning algorithm, to ensure product quality. They have been using it as a visual inspection tool to check parts for defects and have achieved 99% accuracy along with improved reliability and cycle times (Hachem, Perrot, Painvin, & Couturier, 2021).
If you need support in evaluating the use of an automated system to improve product quality, the experts at EMMA International can help! Call us at 248-987-4497 or email us at info@emmainternational.com to learn more.
