Quality Management: KHS Provides New Groundbreaking Inspection Technology
Centralized intelligence: all inspection systems at a glance
Consumers want high-quality products. Yet without intelligent inspection systems, it is almost impossible to produce the same high-quality workmanship over a long period of time. The only question is how many inspection locations must be monitored. The answer lies in the new Innocheck quality assurance system that combines all inspections in one intelligent system – and all at once. Beaches, palms, sunshine – isolated islands are much sought after by holidaymakers. In contrast, in quality management isolated systems, even when networked, seem like relics of the past: isolated, incompatible, and almost impossible to extend. “Inadequate flexibility in the interaction of inspection systems is an obstacle to any further development,” comments Jan Peter Hecktor, Head of Product Management Competence Center Inspection Technology at KHS. Centralized Innocheck inspection technology KHS has now developed innovative inspection technology for the future with a common platform for all inspection applications. Jan Peter Hecktor says, “With our new, integrated quality management we are beginning a new era, moving away from networked isolated solutions towards one inspection technology concept." And what about the dedicated spare part warehouse, dedicated software and sometimes even dedicated service technicians for each and every component? With the new quality assurance components in the Innocheck series, there's no longer any need for all this. In the future, all of the measurement bridges will receive their control orders from the new Innocheck CUB control unit. This is based on one and the same software and hardware, is modular in design, and comprised of proven, long-lasting industrial KHS components. Prepared for modular hardware extensions When a computer module in the control unit reaches its limits, you only need to open the CUB terminal and insert another module. Insufficient compatibility and complicated adjustments when connecting new hardware are things of the past, as are extensive spare part warehouses. Just one single software platform … “Of course, sophisticated hardware is only as good as its associated software. Our goal was to create a Plug & Play system that is guaranteed for the future and offers the customer the greatest possible flexibility”, Hecktor says. Whether tamper-evident seal inspection, leakage check, or bottle alignment, label inspection, rejection, crooked cap inspection, or bottle tracking, all the inspection technology components will in future obey the commands of the Innocheck CUB software platform. … with an integrated library The integrated library keeps the necessary program parts available. This sounds complicated but isn’t. For example, a beverage manufacturer would like to check that the caps are straight on the bottles on the filling system. The inspection unit for crooked caps, Innocheck Crooked Cap Inspection (CCI), is quickly installed, configured, and connected up. An employee then assembles the required command sequence with the help of ready-made program elements. Step by step, this goes as follows: _ First, the software finds out which tasks the CCI camera and lighting are to perform. _ Next, the individual program sections are selected that could simply be referred to as ‘Find camera data’, ‘Select image section using defined parameters’ or ‘Check gray value distribution’. _ As soon as the command sequence is complete and all the necessary parameters have been entered, the inspection unit is ready for cap inspection. Experienced employees can set this up in a few minutes. However, it can all be even simpler. KHS also provides configuration files with standardized command chains for each application. Once the hardware has been installed, only a few clicks are needed to activate the proven, standardized command chain. Systems capable of learning To make things even easier, on request KHS software can learn independently through constant dialog between the control unit, machine, and inspection technology. The only prerequisite in labeling perhaps are the reference values. These can be entered in the traditional way or learned by feeding in bottles marked ‘good’ or ‘bad’. Sensors and cameras register the differences between correctly and incorrectly applied labels. They register items such as bottle type, label position and alignment, and independently look for suitable distinguishing criteria. Finally, the system analyzes the available tolerances and sets the operational limits. Quality expert Jan Peter Hecktor concludes, “In case something goes wrong during the production process, the KHS software provides interesting functional solutions.” Instructions on how to act in particular cases of error can be stored even when the production line is being set up. This is sheer efficiency! The same applies to operation. The touch screen on the CUB control unit always shows the same GUI with its structured design; it always has the same outfit with the same command buttons and intuitive pictograms. Only the language varies. Anyone familiar with operating this CUB control will then be able to cope with any other KHS component in this series of products. Moreover, since all of the Innocheck series inspection applications can be configured individually and adjusted to suit customers’ particular requirements, the error rate is reduced to a minimum. System efficiency increases and production costs drop. In addition, all processes, including statistical data, can be tracked at all times. This is an efficient, attractive brand of quality management. Only holidaymakers still dream of isolated solutions.