Elevate industrial efficiency with Predictive Maintenance as a Service (PdMaaS), outsourcing to expert vendors for cost-effective, scalable, and rapid implementation,…
A leading producer of plastic tubes for common household items, faced challenges in the production process. The complexity of manufacturing plastic tubes, essential for products like toothpaste and mayonnaise, brought forth issues related to efficiency, quality control, and cost-effectiveness. The need for precise control over lacquer coverage, welding quality, and overall product inspection posed significant hurdles.
Seargin addressed Client’s challenges by implementing an advanced vision system throughout the production process. The system comprised a line camera, adjustable lighting with various angles to accommodate different types and colors of film, and machine learning algorithms. This system ensured the maintenance of a 5mm lacquer-free margin on both edges, a critical requirement for proper sealing, thus ensuring product quality and cost-effectiveness.
In the welding stage, a vision system equipped with a 12MPix camera, macro lens, specialized illuminator, and deep learning software monitored the weld quality. Detection of poorly sealed tubes prevented potential ruptures during pressure filling, saving materials and guaranteeing high-quality production. The final inspection phase utilized a vision system with a 5Mpix camera, telecentric lens, custom lighting, Cartesian robot, positioning device, and advanced image analysis software. This automated process identified creases, deviations from roundness, and contaminants at the tube’s bottom, eliminating the need for manual quality control and enhancing efficiency and accuracy.
The implementation of Seargin’s vision system yielded substantial benefits for the Client. The reduction of waste to a mere 3% resulted in approximately $400,000 in annual savings. The strategic investment in the vision system not only optimized the plastic tube production process but also significantly improved product quality and contributed to sustainability goals. By eliminating the need for manual quality control, efficiency and accuracy were enhanced, aligning with Client’s commitment to innovation and efficiency in manufacturing.
Financial Savings: The producer achieved an annual saving of approximately $400,000 through a remarkable waste reduction to 3%.
Enhanced Product Quality: The implementation of the vision system ensured precise lacquer coverage, high welding quality, and thorough product inspection, contributing to an overall improvement in product quality.
Sustainability Contribution: The reduction in waste and increased efficiency align with Client’s sustainability goals, making the production process more environmentally friendly.
In conclusion, Seargin’s solution not only addressed the specific challenges faced by the Client in plastic tube production but also proved to be a transformative investment with far-reaching positive effects on efficiency, cost-effectiveness, product quality, and sustainability.
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