Martin Lehmköster

Place for, company logo from speaker Reduction of Downtime, Quality Improvement and Customer Satisfaction with High Speed Web Inspection Systems Martin Lehmköster 7.1 7632

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection cameras light GUI 4. Classification higher ROI 5. DataMining make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 2

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection cameras light GUI 4. Classification higher ROI 5. DataMining make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 3

ISRA worldwide LANSING HERTEN (Germany) web inspection center SHANGHAI ATLANTA DARMSTADT ISRA AG TAOYUAN world leader in web inspection more than 3500 systems installed 280 employees 7.1. 7632 Martin Lehmköster 4

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity -examples 3. Basics of web inspection cameras light GUI 4. Classification higher ROI 5. DataMining make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 5

Situation We are facing the fact of increasing production costs due to: Increasing Raw Material Costs Increasing Energy Costs More critical Customers At lower market prices for the products on global markets! 7.1. 7632 Martin Lehmköster 6

Avoid costs of machine downtime detected defect in paper (hole and contamination) caused machine stop in the print machine 7.1. 7632 Martin Lehmköster 7

Web Inspection Finds your defects as early as possible to document and classify the defects to take corrective action to avoid more defects to avoid processing scrap and low quality to avoid customers complaints 7.1. 7632 Martin Lehmköster 8

Reduce costs of quality change in raw material Blown film, transparent, tubular film, transmission Width: 400mm, v = 80m/min Change of pellet at 9800m 7.1. 7632 Martin Lehmköster 9

Reduce costs of quality change in raw material Blown film, transparent, tubular film, transmission Width: 400mm, v = 80m/min Change of pellet at 9800m 7.1. 7632 Martin Lehmköster 10

Uncritical defects PVC, calender, transparent, transmission, v=50m/min 7.1. 7632 Martin Lehmköster 11

Critical defects PVC, calender, transparent, transmission, v=50m/min 7.1. 7632 Martin Lehmköster 12

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection cameras light GUI 4. Classification higher ROI 5. DataMining make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 13

System-Architecture Cameras Position Encoder Illumination Cabin Data base Operating unit 7.1. 7632 Martin Lehmköster 14

System overview Data base Display of inspection data Reports Alarm signals Interface to networks 7.1. 7632 Martin Lehmköster Statistic 15

System for diaper film/ nonwovens 7.1. 7632 Martin Lehmköster 16

System for paper Cameras: 8 (2.048 pixel) Machine: PM#25 Width: 5.000 mm Speed: 1200 m/min Illumination: LED white Resolution: MD: 0.71 mm CD: 0.38 mm Rewind-Manager Marker: Ryeco 6 color 7.1. 7632 Martin Lehmköster 17

Light sources fluorescent light - cheap - simple maintenance LED - free of maintenance Special development??? Reflection Transmission 7.1. 7632 Martin Lehmköster 18

Ultrabright LED Light Line lifespan: 10 years! 7.1. 7632 Martin Lehmköster 19

Many pixels for the right decision Web inspection can handle 320 Megapixel / sec per camera 7.1. 7632 Martin Lehmköster 20

Resolution and Speed resolution Speed of the camera is the key for high quality images! 7.1. 7632 Martin Lehmköster 21

Large Images on Demand Dielines in transparent film of 250µ 7.1. 7632 Martin Lehmköster 22

Advantages More pixel better resolution More pixel better pictures More pixel better defect detection More pixel better defect classification 7.1. 7632 Martin Lehmköster 23

User verification High Resolution Images = Accurate Classification Identify Defect Cause & Take Corrective Action to Eliminate Defect 7.1. 7632 Martin Lehmköster 24

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection 4. Classification higher ROI 5. DataMining make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 25

Criteria for a simple/ single classification? Criteria: Box - Classifier - bright / dark -area - lenght / width equal? 7.1. 7632 Martin Lehmköster 26

A Learning System for Classification A A A A A A letter = A B B letter B = B 7.1. 7632 Martin Lehmköster 27

B Classification with Quick Teach Reliable classification Z V S D S I = this is the letter A B W B @ B () () E Ü P... even with noisy background! 7.1. 7632 Martin Lehmköster 28

Requirements for classification High accuracy Simple operation with images Display of human classifier - high amount of criteria Easy modification/ high flexibility Real time ability/ immediately response Intuitive operation 7.1. 7632 Martin Lehmköster 29

Box-classifier Only for simple criteria: - area, length, width Simple manual definition Unqualified for complex tasks Danger of forgotten! Division of defects according to simple criteria Pseudo defects! Very good and stable solution for simple task should be included in every system as a plain classifier. 7.1. 7632 Martin Lehmköster 30

Today: Next neighbour -classification Self-learning classifier Mathematics is hidden Easy modification Little basic information (Images) necessary No over-teaching possible Anytime extendible Avoiding pseudo-defects A fast learning classifier gives a higher ROI 7.1. 7632 Martin Lehmköster 31

Fast learning classifier! results? Get your production run at once with a classifier time - do not waste time with teaching a classifier 7.1. 7632 Martin Lehmköster 32

User-friendly learning The user selects a defect out of the continuous production Easy to understand, easy to operate Guarantee for quick implementation Description Saving of information back to data base of system 7.1. 7632 Martin Lehmköster 33

Learning Requirements Classifier needs image gallery For every defect class images must be available Images will be collected during production automatically 7.1. 7632 Martin Lehmköster 34

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection 4. Classification higher ROI 5. DataMining make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 35

Data Preparation reducing data to a reasonable extent Defectdatabase + e-mail list Time table Individual report 7.1. 7632 Martin Lehmköster 36

Example: Single lane report to rate quality 7.1. 7632 Martin Lehmköster 37

STEP III global network central data mining 7.1. 7632 Martin Lehmköster 38

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection 4. Classification higher ROI 5. DataMining make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 39

Marking defects 7.1. 7632 Martin Lehmköster 40

Winder Interface & Control Main Inspection System Configuration Data Defect Data Rewind Manager Rewind Controls PLC 7.1. 7632 Martin Lehmköster 41

Defect Marking and Web Position Synchronization Start 0 1 1 0 Defect Mark (Bottom Side) 1 1 0 0 0 1 Web Sync Marks (Top Side) ½ 7.1. 7632 Martin Lehmköster 42

Rewind Manager total system solution Rewind Manager to automatically stop re-reeler for defect removal Defect marked at defect location on top surface Codes marked on bottom surface Mark Reader controls reel map display to show image and location of next defect to stop on Operator override to skip defect Rewind Manager Sending slow down pulse 2000 ft before defect PLC Decode Barcode PLC Break Control 7.1. 7632 Martin Lehmköster 43

Rewind Manager Screen - Map Defect filter Current Position Next defect on the web 7.1. 7632 Martin Lehmköster 44

Rewind Manager - Defect Selection Stop on Defects in Red Click on a defect image to toggle stop status 7.1. 7632 Martin Lehmköster 45

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection 4. Classification higher ROI 5. DataMining make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 46

Validation by artificial defects Image of an artificial defect 7.1. 7632 Martin Lehmköster 47

Validation by real defects Electronic masking of real defect images Signal Signal 7.1. 7632 Martin Lehmköster 48

Advantages of high-end web inspection Reduction of - customer complaints -of waste -of downtime - of costs Deliver proven quality High return on investment 7.1. 7632 Martin Lehmköster 49

Thank you for your attention! Thank you for your attention! Questions? Martin Lehmköster ISRA Surface Vision GmbH Albert-Einstein-Allee 36-40 45699 Herten Tel. +49 2366 9300-0 info.surface@isravision.com 7.1. 7632 Martin Lehmköster 50