Automatic Optical

Inspection


MALTA
WHAT IS AOI ?
AOI stand for Automatic Optical
Inspection.
The AOI system checks the boards to
ensure that the components are present,
not skewed and are located properly in the
X and Y directions.
It checks component polarity if clear
orientation marks are present on the
component body.
It even checks 2D paste deposition also.
And displays result.
WORKING PRINCIPLE
The SJ utilizes user Computer Aided Design (CAD)
data in conjunction with its robust vision algorithm
database to recognize and accurately locate all
board components on a PCB.
Here cad data is used to locate the component (x-y
coordinates). Where as vision algorithm analyses
and reveals the components physical properties.
In general an algorithm is set of instruction and
procedure to perform a task.
In this case the task is inspection.so each group of
components has different algorithms.
Example:- chip resistor & capacitor, these
components has different physical appearance
and capacitor may be polarized . Hence different
procedure is needed .


MACHINE OVERVIEW

Modelling and Detection
Sometimes industry and academia refer to
the same concepts differently
A Unified approach was developed for dealing
with scheduling problems using available data
Our approach is based on a graphical
representation
Modelling allows us to
find out
which problems
require academic
attention
help us find existing
research
Optimisation
Providing a generic optimisation tool for diverse
production line is very difficult
The focus is on scheduling orders, not planning
Tools must be adapted for individual production
lines
Suitable for fast scheduling and what-if
analysis

Example in case of
machine breakdowns or
for configuration changes
Optimisation
Tools Provided
Optimisation of Single Machine problems
Very common for SME manufacturers
Optimisation of Job Shop Problems
Very common with Multi-Stage Production Lines
Handling of Parallel Sequences
When some sub tasks are done in
parallel to the main task to speed
up process (e.g. preparation of
basic components)
Handling to setup time between
different jobs
Machine Reconfiguration
Support for release dates and
deadlines
Process 2 Automated QA
for Print Output
using Neural Networks
Automated Optical Inspection Motivation
Quality is a key factor in the selling price of
manufactured goods
Quality inspection is traditionally carried out by
human beings either:
At the end of the production line on each and every
item removing defective products (slow and
expensive)
Or, inspecting samples from a produced batch and
assessing a batch quality (defective products are left
in batch)
Although some automated off-the-shelf tools exist,
these are usually too general and fail to identify
certain defects
Defects
Missing or incorrectly placed components
Scratches and cracks
Print offset, missing/extra transfer of ink
Smudges and misalignment defects
caused by multiple printing on location
An Automated Inspection System
Reliable 24x7

Accurate

Fast

Consistent

Cheap

Automated Optical Inspection
Image
capturing
Image correction,
background
removal, alignment,
segmentation
Further image
processing and
feature extraction
Data Input to
Classifier and other
QA tests
Output from
Classifier

Setting up the system
The system can be configured
to perform a number of QA
tests depending on the product
and type of defects

A product representation is built by the system
based on one or more of the following
A single product and some parameters
A number of defect free samples
Both defect free and defective samples

The two steps of AOI
System is split up into two main modules
Image Processing
Alignment
Background Removal
Segmentation
Inspection
Feature Selection
Colour Inclusion
OCR
Label location
Neural Networks (WISARDs)
Practical use of ICT in
Manufacturing A Case Study


Testimonial: Mr Olaf Zahra
Toly Products Malta
Toly Products is cosmetic packaging solution provider for the
beauty industry.
Toly Products has been manufacturing in Malta for the past
40 years. Today the majority of corporate function are also
located her.
Our factory here (and in other countries) operate on lean
manufacturing principles. We manufacture only to order on
the date the product is required
We produce between 1.5 to 2 million units per week
We have over 2,500 different live products
Process 1 Automated
Optimisation of
Production Lines
Research Benefit
Scheduling is a critical function:
Impacts manufacturing efficiencies.
Impacts delivery and customer satisfaction
Impacts reputation if deadlines are missed

Good scheduling requires
Skilled operators who know the processes well
Involvement of several key departments and functions/
Good regular feedback from the production floor.

Since 2008 this criticality has increased exponentially. In a
downturn, organisations try and release cash and in our industry
this was done by reducing stocks. As the market recovered the
new limits set on stockholding have been maintained. For an
upstream manufacturer this means shorter runs and more
frequent changeovers.

Major Challenges
A lean manufacturing set up requires components to be
continuously in motion from the beginning to end of the process to
avoid bottlenecks and the build up of stocks. It also requires
materials to be delivered to the production floor when and as
required.
A large variety of products for different clients
A bewildering combination of mould tools and moulding
machines that need to be configured for different jobs
Finding a good balance between technical and human
constraints and meeting client demand
Delivering to the customer On Time and In Full.
The aim is to
Minimisation of downtime
Minimisation of work in progress
Maximising resource utilisation
Exploring Possibilities
Achieving better results while maintaining
a flexible manufacturing environment
Explore different possibilities of
allocating resources to manufacturing
Gain future insight to help sales and
marketing personnel plan orders
Work around scenario changes in cases
of schedule disruptions (e.g. urgent
jobs)
Achieving the target
Having several scheduling possibilities allows for
more accurate planning.
Functions have better visibility of the tasks they
are required to perform to service the plan.
Minimising job changeovers reduces delays and
maximises overall plant efficiency

Benefits
Some of the benefits offered by the
system
Effective planning tool
New approach to scheduling
Cost Effective
Fast Results
Configurable
Low training requirements
Uses information we already have and know
about
Process 2 Automated QA
for Print Output
using Neural Networks
Visual Inspection at Toly
Production of luxury cosmetic packaging for the
beauty industry.
Visual quality is of utter importance
Even using state of the art machinery there are a
multitude of parameters therefore variation is a fact of
life. Inspection needs to identify this variation before it
exceeds the permissible tolerance so that defectives
are avoided and the process can quickly be brought
back in line.
Visual defects consist of
Bad Printing (location, missing/extra ink)
Incorrect assembly.
Scratches, cracks or smudges

Challenges in the inspection process
Currently visual inspection is carried our in one of two ways
Manual Inspection
Advantages
The inspector can identify and classify small variations from product to product
and take a call; i.e. is flexible
Drawbacks
Tedious
Inconsistent
Slow
Inaccurate
Current (at Toly) camera based automated inspection technology
Advantages
Accurate
Consistent
Fast
Drawbacks
Limited application.
Inflexible; it works with strictly defined parameters therefore typically will reject
numerous good parts with the bad parts
Using the system
The system is configured with few
parameters and provided with a number of
defect free products.
System then trains and builds a multi-
layered model for that particular product.
The model is saved and used every time
that the corresponding product is
manufactured avoiding the need of
reconfiguration
Benefits of the system?
The system is able to identify defects on our
products from several good and several bad
images. Therefore it builds up a memory of
good parts which allow it to widen its
tolerances over traditional systems.
It is applicable to a wide range of products
and also a wide range of defect possibilities.
Easy to set up and easy to update once a
new defect has been encountered.
Summing it all up
The system is preferred over manual
inspection
Reliable
Avoids manual contact of the product
More accurate
Faster
Consistent







Thank you for
listening