Zero Defect Manufacturing
Assembly Line
Industry 4.0 and the pursuit of resiliency
There are two parts to the Zero D story. Visual inspection and asset performance management (APM). Visual inspection uses computer vision models focused on quality inspection. APM uses machine learning models based on time series data to determine health of assets and probable failures in the future. Toyota is using Maximo Visual Inspection, and now they are also using the Maximo Asset Performance Management (APM) suite. They tested Maximo APM on some of their machinery that does liquid cooling and found that was another problem area for them. By implementing the software into this pilot, they are now able to monitor the asset health 24×7 and predict probability of failure in the future.
Computer Vision Advances Zero-Defect Manufacturing
A key part of the process it wanted to automate is server assembly quality assurance, which was being done manually by quality operators. This labor-intensive process is prone to error due to human eye fatigue and the inability of quality operators to catch critical defects.
This situation is hardly unusual. According to Kemal Levi, Founder and CEO of Relimetrics, there is “a strong demand for computer vision to replace manual visual inspections. Yet, due to a high production variability, particularly in the case of discrete manufacturing, computer vision systems today are not able to keep up with the rate of change in configurations.”