An article I was able to be a part of with one of our larger international clients.

1. MINDUSTRYffi
COVERINC INDUSTRY IN THE ONTARIO-MICHIGAN TRADE CORRIDOR
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A|AX, ON - Responding to the cost, reliability and quality control issue was that as a supplier we were looking for improvements in the
requirements of its customer, automotive supplier Lear Corporation is quality control process. Statisticalanalysisshows manual inspection is
adapting advanced vision inspection systems at its Ajax and Whitby only 85o/oeffective. We continually need to find ways to tighten up our
plants. The nearby plants supply Ceneral Motors of Canada's Oshawa- inspection systems so that we become more reliable and consistent
based truck and auto assembly plants respectively. across shifts."
Tim Lyons, plant manager of the two Lear plants, saysthe flexibility and Howeve6 there were strict guidelines. The cost of vision systems had to
adaptability of vision inspection systems supplied by Markham, ON- be offset by the reduced cost of employee involvement in the inspection
process.The supplier also had to overcome the issue of "false failure", in
based Global Controls Inc. make them a good application for the seat
which parts are incorrectly rejected during the automated inspection
production facilities.Global Controls designs, integrates and maintains
process. Lyons says if the false failure rate is high and occurs on a regular
turnkey vision inspection systems for the electronics, automotive and
basis, it becomes a nusianceand distraction for supervisors deal with.
to
pharmaceutical industries.
Lear's Ajax plant, with 96,000 sq. ft. of manufacturing floor space,
PROIECT GUTDELTNES produces several seats combinations that are installed in GMC and
Lyons says Lear considered the Clobal Controls automated system for Chevrolet extended cab and crewcab pickup trucks. The plant currently
initial application at its Ajax plant for two reasons. "We are always has about 30O employees in five-day, two-shift operation that shipped
looking for ways to automate our processand reduce costs.The second approximately 900 front and second row seatsdaily during May 2008.
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2. The first automated vision system application, which began in 2QO7, EXPANDABTTITV
involved a 12-camera station. Project leader Edward Lee of Global "One of the good things about this technology is that it allows us to use
Controls worked closely with Mike Downey, a member of the it for different applications. lt's expandable so it allows the customer to
continuous improvement team at Lear Ajax, during the project purchase2-3 camerasdown the road and install them for specific needs.
specification, integration of the vision system hardware and software It's a very adaptive process so your hands aren't tied once you put the
and launch stage. Global Controls uses software provided by system in place." Adaptability of the equipment is also consistent with
CanaVision Technologies to link multi-camera system solutions that the continuous improvement program at Lear.
a r e c u s t o m i z e d t o i n d i v i d u a l a p p l i c a t i o n s .C a n a V i s i o nh a s a 1 S - y e a r
Lyons admits that variation in the production process and product
history of developing image processing algorithms to automate
components posed a challenge for the automated visual inspection
inspection tasks that normally are performed by the human eye.
system at the outset. "Global Controls was able to adapt to an
The system utilizes a validation matrix and adjusts readily to inspect
engineering change on a part that we had. The vision system had to be
different seating systems without requiring camera positioning
adjusted to match the new spec from the change of part."
adjustments. The system also provides full part traceability with
images and data.
TRAINING
For the initial project key Learemployees received basictraining on how
Prior to installation of the cameras, one employee per shift was the system would work. For a subsequent project, Clobal Controls will
dedicated to visual inspection of the back of the seat assemblies. train Lear programmers to work with its automated camera system. This
Now the cameras perform the visual inspection in an approximately will involve less reliance on the supplier for minor work. "This will open
8 foot by 4 foot location near the plant's main repair area. A reduction up our opportunity to expand the system over time and also achieve
in manpower by two inspectors resulted from the installation. Lyons some cost control," Lyons says.
says the camera system is fully automated, recording images
automatically as product arrives at the inspection area. "lt is very Lear employees visited supplier headquarters in Markham to view an
simple to work with from a user standpoint." offline model setup with seats prior to actual installation at the Ajax
plant. Lear also 6enefits from remote monitoring support of its
"The vision system has improved our inspection process. We have assembly line from Global Controls' headquarters.This allows for online
a good solid system in place to catch any defects. The system has trouble-shooting with built-in diagnostics. Remote monitoring benefits
Lear because it can call for assistanceand get the support it needs
helped us drive variation out of our process."
within minutes. This is absoulutely critical in a f lT operation.
The same cameras apply the same set of criteria for each product
"What makes it even better is that when you have product issuesthat
inspection during a shift, recording tethers, snaps, bolts and
are subjectivein nature like, say wrinkles,you can redefine it (the inspection
orientation before the product is approved and shipped into finished
acceptance criteria) after a period of time," Lyons says. "We have
goods inventory. lf the cameras find a defect, the system drives the
improved our systems so much in the upstream production area that a
product into repair. After repair, it goes back into the system for
more consistent and reliable product is now leaving the downstream
another visual inspectionby the camerasprior to shipping. shipping area after the cameras inspect it." The camera monitoring
systems can be easily modified to allow for higher levels of acceptance
Lyons says his previous experience with vision systemswas unconvincing. requirements.
"Other systems that l've seen in the past had a hard time in
eliminating falsefailure. lf an inspection system fails so many seats Lyons says he expects that the successthe Ajax plant has experienced
on a regular basisand there is actually nothing wrong with them, with automated vision will carry over to the Whitby plantfor an inspection-
it becomes a problem for our management team and actually oriented camera application in the shipping area. "l'm very pleasedwith
hinders efficiency. This vision system that Global Controls provided the way the initial project worked at Ajax and that we can take it to the
h a s b e e n v e r y g o o d a t m i n i m i z i n g t h e s e f a l s ef a i l u r e s . " front line at the Whitby plant."
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