QUALITY 4.

0: AI-based
Computer Vision Brings
Actionable Insights to
Manufacturing
October 12, 2022

Adam Bennett
Learning Objectives
• This session:
! Industry experts can be EMPOWERED by
no code/low code Computer Vision and
analytics of visual data.
! Capabilities of AI-based Computer Vision
! Use Case/ Application examples
! Deep-learning vs. traditional Rules-based
Machine Vision
About the Speaker
• Enterprise Sales & Product
Development/Management
• Emerging Technology for Manufacturing & Logistics
! Machine Vision (10 yrs) - 2D & 3D imaging
technologies
! RFID, BLE, and other wireless communications
! Machine Controls
! Product Transport Technologies - electro-
magnetic and levitation technologies
! And more…
 Perception Through Sight

• Sight is most impactful

• 80% of all impressions
• Augment machine vision &
supervisory systems
• Detect/Classify
! Defects
! Objects
! People
! Actions
! Events
Machine & Supervisory Perception

Rules-based Approach
• Pixel count
• Pixel color Camera
• Shape
• Machine Vision
Expert
• Etc.

User-defined Rules Lighting

Results

Data
Part
Machine & Supervisory Perception

Deep-Learning based Approach Team Synergy – Subject Matter Experts

• SME’s (Quality, Engineering,

Production)
• Examples
• Feedback (SME’s)
• Learns
Computer Vision Platform

Results Neural Networks Quality Engineering

Feedback
Rules
Data
Production
Computer Vision – Hardware Agnostic

• Device Type:
! Digital Borescopes
! Digital Microscopes
! X-Ray
! Industrial Cameras
! Security Cameras
! Smart Devices (phones, tablets, etc.)
! And MORE…
• Media Type:
! Image based
! Video based
! Live Stream
Benefits of AI-based Computer Vision

Demand Drivers:
• Defects that vary in shape & size
• Inspect product that varies – mass
customization
• Changing ambient conditions (lighting,
tooling, etc.)
• Personnel turnover (tribal knowledge,
experience, etc.)
• Manual Operations – human actions
SEE IT. DETECT IT.

TAILLIGHT
TAILLIGHT
BUMPER MOUNT
Most Challenging Defects

Weld classification – Improving feedback to welding systems

• Good/complete
• Porosity
• Spatter
• Burn through
• etc.
Invisible to the Human Eye

Nondestructive Testing – Leverage additional imaging techniques

• X-ray
• Magnetic Particle Inspections – UV spectrum
• SWIR – Short-ware Infrared
Tiny Defects
Pitting – even on heat treated metal
• Defects vary in shape, size, and
color tone

Electronics & semiconductor

• Digital microscopes help us
visualize the smallest of defects
• Use any resolution of imagery
 Material Classification
• What material?
• What percentage of material is in my
product?

Porous calcareous Massive calcite- Massive calcareous Bioturbated siltstone

siltstone cemented siltstone siltstone
Identify Objects – Kitting & Assemblies
Identify Objects
Actions – Pose Estimation
Action Detections
Actions – proper sequencing
Events – Cycle time vs. Idle time
Operation 1 Operation 2 Operation 3
Cycle1: 57.19 Cycle1: 74.83 Cycle1: 210.45
Idle : 23.05 Idle: 10.25 Idle: 45.27
Cycle2: 54.24 Cycle2: 76.67 Cycle2: 215.34
Idle: 22.39 Idle: 12.13 Idle: 57.44
Cycle3: 56.79 Cycle3: 89.67 Cycle3: 245.75
Idle: 24.67 Idle: 10.48 Idle: 46.72
Cycle4: 56.12 Cycle4: 77.54 Cycle4: 213.68
… … …
Events – Where is time spent

Zone 1: 40.62

Zone 2: 196.12

Zone 3: 13.36
People/ Safety/ PPE
People/ Safety/ PPE
Feedback Loops
Feedback Loops - Machines

• Detection of splits/cracks and

scoring
• Adjust speed or lubricants

Source: https://www.gettyimages.com/
Feedback Loops - Machines

• Detection of short shots

• Adjust mold machine
pressure/temp/time

Source: ptonline.com
Feedback Loop – Manual Assemblies

• Identify human errors in wire assemblies

• Give direct feedback to operators
Analytics - Manufacturing

Capture analytics
• When, how many, frequency
• Upstream/ downstream
bottlenecks
• Operator performance
• Trends / Patterns / Anomalies
• Root cause
• Defect classifications
• Video playback
• Etc.
Detect, Analyze, Improve
Interactive Detection Calendar

Detection Data and Playback

• Detection timestamps
• Snapshot of detection
• Video summary of events before,
during, and after
Getting Started | AI-based Computer Vision

Assessment Business/Operations Impact

• Review operations and • DMAIC
challenges • What operations or products
• Identify most impactful have the largest impact on the
production line or stations to production site/ enterprise
focus on • What’s the risk of doing nothing?
• Develop a PoC with a SoW • What has to be achieved to bring
defining the timeline and a ROI?
outcomes (typically 3 months)
Ramp-up
• A tailored approach for scaling
computer vision across
production
Building Custom Detectors

Developing your custom detectors

• Build - Define what we are detecting, image
formatting (industrial camera, security camera,
digital microscope, etc.) collect examples, train
Quality Production Engineering
detector
• Test – Ensure the detector has learned and
performing well
• Deploy – Run detectors in production
• Manage – Team collaborators (quality, controls,
line supervisors), system feedback, version
control, immutable traceability
Results Neural Networks

Feedback
Rules
Data
Summary

• AI-based Computer Vision:

! Detect/classify
your most challenging defects, objects,
people, actions & events.
! Use any type of camera technology providing image, video,
or live stream.
! Detectors help catch quality issues, get to the root cause
faster, and provides analytics to understand patterns for
operational improvements.
! A collaborative approach for AI-based inspection.
 Questions?

Adam Bennett – Phone: 904-562-0171 – Email: adam.bennett@matroid.com