The system operates on a PC processing platform, offering high processing speeds and system flexibility to run many of the unique features of the WebSPECTOR system. Speed limitations are usually due to web handling rather than the inspection system itself.
There are a number of ways to consider this question. Generally the first is whether to install it onto an existing process line, or as a stand-alone purpose built batch to batch machine.
Each has benefits; online provides reduced handling and an inspected batch directly off the process (and for some processes, such as coating, the severity/length of defects can be reduced to a minimum). Whereas a purpose built high speed batch to batch machine often allows the output from more than one process line to be inspected with a single system.
However there is a wider consideration in terms of the best use of vision systems in a manufacturing process (which may not be completed on one site). This involves a broader implementation of the technology throughout the production process stages, creating significant saving by replacing high cost external waste (customer claims/reject), with lower cost, early internal intervention to remove sub-standard product. The same total volume of scrap is removed from the system in both cases, but internal control is generally much more cost effective before full value has been added and (critically) before it gets to your customer, where additional costs may be incurred and claimed, such as shipment costs, lost process time, additional added value from their process etc.
Often an increasing proportion of value is added at later stages of manufacture that involve higher process/component costs, so substantial costs can be avoided by early detection and not processing already substandard product.
The system detects defects and produces an electronic map of the batch with defect images and locations. It can trigger alarms for critical defects and apply labels in line with defects. The defect map is reviewed for commercial acceptability and used to create an optimized cutting plan. Additional outputs include analyses comparing raw material suppliers and sets of process machines.
The system is configured based on typical defects provided by you and evaluated by us. During commissioning, our engineer uses the WebCORDER feature to compare inspection maps with manual inspections, making adjustments as needed. The recording feature allows repeated validation without rerunning the fabric.
The system automatically trains itself on each style/product, ensuring optimal inspection settings without operator intervention, even with thousands of different styles.
The system accepts product data from networked production control systems, bar code scanners, and manual entry. It detects transitions between products to adjust settings automatically.
Yes, the system allows individual settings for each product and customer combination, which can be adjusted as needed.
No, the system automatically identifies features that deviate from the normal web surface, classifies and grades them in real time using AI and the CBIGS classification engine.
Yes, the system uses a real time AI powered defect classifier that recognises defect features and can accurately assign them to not only the defect type, but to pre-defined grades of each type, which then triggers the output action of the system, such as applying a label or filtering out non critical defects, or indeed stopping the line.
Yes, the CBIGS feature uses many mathematical properties of each defect to accurately determine the seriousness of a defect. These properties are used to produce accurately graded defect maps.
Yes, authorized users can edit electronic maps to meet commercial requirements.
The standard system uses monochrome cameras which are suitable for most applications and are used for detecting shade changes. Full colour cameras are used where required.
No, the system automatically switches inspection parameters in real time and trains itself on new products without operator intervention.
Yes, the system is adaptable for all textiles and various web-type products including paper, plastic film, nonwoven, fiberglass, coating, metal, and glass.
Yes, the PC-based processing platform can be upgraded with newer models to increase speed significantly at a low cost.
The system reduces labor costs, increases throughput speeds, optimises sales value by minimising waste (thereby increasing yield) and improves control over production quality.
Typically within 18 months, and in some cases less than 12 months. Contract rental schemes may provide returns in under 6 months.
In some cases there will be the opportunity to significantly improve the yield of a batch by editing the map, or by having more flexible optimisation rules (such as increasing the roll length tolerance). The great significance of running the optimisation on an electronic, or ‘virtual’ map, is that you can be certain of the outcome of the cutting process before the batch is cut. This process can be viewed and decisions made remotely, for companies with offshore or multiple manufacturing plants.
With the power of visual records you keep from the system, you will have more information about your products that your customer. The consistency of the system performance means you can be sure the inspection has been performed to the agreed level and in fact the settings can be audited. Once your customer knows you are in control, our experience has been that they think twice before making claims and more importantly, the reasons for claims are removed. This leads to a considerable reduction in cost for both parties commonly involved as a result of claims and in resolving them (lost production, planning logistics, airfreight, re processing, value added compensation etc etc). It may well be that you can provide your customer with additional information from your inspection process that would assist their business.
Yes, the system allows remote viewing and operation anywhere with an internet connection. A centralised quality control and sales force can benefit greatly from fast, reliable and consistent quality and shipping data.
Your system will be remotely supported over the internet in terms of software and operational issues. In the unlikely event of component or mechanical failure, we will have trained your personnel to rapidly replace critical components from a stock held on your site to achieve minimum downtime.
The system saves on energy use by reducing the number of machines, minimises waste and disposal needs, and eliminates the need for airfreight and troubleshooting travel.
There are opportunities to work more closely with your customers, for example you could email them the inspection report the instant the product leaves the final process so they could ‘sign off’ the batch before it even enters your warehouse. This gives them the benefit of knowing their production (or sales window if they are a retailer) will not be disrupted by unknown quality issues, late shipments or short shipments. This could be a way of attracting more business from existing customers and/or attracting new customers who would rather place business with an organisation that has your degree of control.
Additionally, if your customer has certain lay planning and production optimising software the electronic defect map can be easily incorporated into their software to optimise cloth utilisation in the panel cutting process.
Once your customer understands the level of control you have from your inspection system they will want to avoid duplication of the inspection process. They would have the opportunity to use the space for more of the value adding activity that would benefit their business.
In the garment business it is more and more important to ensure deliveries are made in full and on time to meet store sales windows as production runs reduce and there are shorter ‘seasons’ in most retail businesses. By eliminating inspection duplication, shipping unknown defects in cloth and providing data to optimise the lay planning and cutting process there is a vast opportunity to streamline the garment value chain, from fabric maker to retailer.
Following intensive and ground breaking R&D the system is now fully capable to inspect all types of patterned fabric, both stable and stretch jacquard, printed and other patterned fabrics at the same speed as plain single colour fabrics. The technique can be applied to fabric forming processes such as jacquard weaving, in process applications such as rotary screen printing and final inspection of finished fabrics.
