KEYENCE: Low-cost solutions: Improving processes and increasing customer trust

Create Date: 2024-8-30 12:03:23|Source: KEYENCE

Background:

A plastics manufacturer has several assembly stations that use automation technology for final assembly. Assembly stations require operators to place certain parts on top of components, such as partitions or packing, before automating a few steps of the process. The company manufactures components that are used in the final products produced by its customers and sold to consumers.

Each component is critical to the final assembly and is a key factor in delivering a high-quality finished product that is built to last. Operators need to ensure that individual parts are in place before they enter the automated process for assembly. Every 30 seconds they have to add up to 5 parts, after which a new round of assembly begins.

Issue:

Operators will keep swapping jobs to stay awake, but there will always be parts that are not fitted to the assembly. This can lead to several scenarios. First, the component damages the component in the automation equipment. Second, the components are damaged and all scrapped. In the third and worst-case scenario, the component is ignored and reaches the customer. Once the finished product reaches the consumer, these parts can quickly fail, causing more problems.

They needed a way to confirm the presence of these parts without relying on an operator. At the same time, these parts must be inspected at a distance. There must be room in the workstation for the operator to move around freely. Parts are made up of several different types of materials, with different colors and reflectivity.

Solution:

There are two types of KEYENCE sensors that can be used to identify parts. The PZ-V/M excels at detecting light brown or black fillers and is a low-cost solution that ignores color changes and provides stable detection even beyond 300 mm. The LV-H series can be used for the rest of the components. Its long-range detection capability and small beam points excel at detecting partitions or liners in confined spaces.

After a very small amount of work, these sensors are retrofitted to the workstation. Because it can detect a wide range of products over long distances, the mount allows the sensor to be mounted so that it does not interfere with the operator's movement.

Outcome:

BY PARTNERING WITH KEYENCE, THE COMPANY HAS INCREASED PRODUCTION BY ELIMINATING THE TIME THAT OPERATORS SPEND VISUALLY INSPECTING PARTS. Because missing parts are immediately visible before the automated process damages the entire component, they are able to reduce material loss. Most importantly, their customers have earned credibility by eliminating long-standing product failures and providing reliable, high-quality products.

KEYENCE: Low-cost solutions: Improving processes and increasing customer trust

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