Martin Lehmkster 7.1 7632 Agenda 1. Introduction to ISRA 2. - PowerPoint PPT Presentation

Place for, company logo from speaker Reduction of Downtime, Quality Improvement and Customer Satisfaction with High Speed Web Inspection Systems Martin Lehmköster 7.1 7632

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection cameras – light – GUI 4. Classification – higher ROI 5. DataMining – make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 2

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection cameras – light – GUI 4. Classification – higher ROI 5. DataMining – make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 3

ISRA worldwide HERTEN (Germany) • web inspection center LANSING SHANGHAI ATLANTA DARMSTADT ISRA AG TAOYUAN � � world leader in web inspection world leader in web inspection � � more than 3500 systems installed more than 3500 systems installed � � 280 employees 280 employees 7.1. 7632 Martin Lehmköster 4

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity - examples 3. Basics of web inspection cameras – light – GUI 4. Classification – higher ROI 5. DataMining – make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 5

Situation We are facing the fact of increasing We are facing the fact of increasing production costs due to: production costs due to: � Increasing Raw Material Costs � Increasing Energy Costs � More critical Customers � At lower market prices for the products on global markets! At lower market prices for the products on global markets! 7.1. 7632 Martin Lehmköster 6

Avoid costs of machine downtime detected defect in paper (hole and contamination) caused machine stop in the print machine 7.1. 7632 Martin Lehmköster 7

Web Inspection Finds your defects as early as possible � to document and classify the defects � to take corrective action to avoid more defects � to avoid processing scrap and low quality � to avoid customers complaints 7.1. 7632 Martin Lehmköster 8

Reduce costs of quality change in raw material Blown film, transparent, tubular film, transmission Width: 400mm, v = 80m/min Change of pellet at 9800m 7.1. 7632 Martin Lehmköster 9

Reduce costs of quality change in raw material Blown film, transparent, tubular film, transmission Width: 400mm, v = 80m/min Change of pellet at 9800m 7.1. 7632 Martin Lehmköster 10

Uncritical defects PVC, calender, transparent, transmission, v=50m/min 7.1. 7632 Martin Lehmköster 11

Critical defects PVC, calender, transparent, transmission, v=50m/min 7.1. 7632 Martin Lehmköster 12

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection cameras – light – GUI 4. Classification – higher ROI 5. DataMining – make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 13

System-Architecture Cameras Position Encoder Cabin • Data base • Operating unit Illumination • 7.1. 7632 Martin Lehmköster 14

System overview Data base • Display of inspection data • Reports • Interface to • Statistic networks • Alarm signals 7.1. 7632 Martin Lehmköster 15

System for diaper film/ nonwovens 7.1. 7632 Martin Lehmköster 16

System for paper • Cameras: 8 (2.048 pixel) • Machine: PM#25 • Width: 5.000 mm • Speed: 1200 m/min • Illumination: LED white • Resolution: MD: 0.71 mm CD: 0.38 mm • Rewind-Manager • Marker: Ryeco 6 color 7.1. 7632 Martin Lehmköster 17

Light sources � fluorescent light - cheap - simple maintenance � LED - free of maintenance � Special development ??? Reflection Reflection Transmission Transmission 7.1. 7632 Martin Lehmköster 18

Ultrabright LED Light Line … lifespan: 10 years! lifespan: 10 years! … 7.1. 7632 Martin Lehmköster 19

Many pixels – for the right decision Web inspection can handle 320 Megapixel / sec per camera 7.1. 7632 Martin Lehmköster 20

Resolution and Speed resolution Speed of the camera is the key for high quality images! 7.1. 7632 Martin Lehmköster 21

22 Dielines in transparent film of 250µ Large Images on Demand 7.1. 7632 Martin Lehmköster

Advantages • More pixel � better resolution • More pixel � better pictures • More pixel � better defect detection • More pixel � better defect classification 7.1. 7632 Martin Lehmköster 23

User verification High Resolution Images = Accurate Classification Identify Defect Cause & Take Corrective Action to Eliminate Defect 7.1. 7632 Martin Lehmköster 24

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection 4. Classification – higher ROI 5. DataMining – make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 25

Criteria for a simple/ single classification? Criteria: - bright / dark Box - Classifier - area - lenght / width equal ? 7.1. 7632 Martin Lehmköster 26

Learning System for Classification letter A letter A A A A A A A = A A = A A A A A A letter letter B B B B = B B = B B 7.1. 7632 Martin Lehmköster 27

Classification with Quick Teach Reliable classification classification Reliable = = I I D D … this this is is the the letter letter A A … S S Z V Z V S S B B B B P P E W E W ... even even with with noisy noisy ... B B @ background! ! background @ () () B B Ü Ü 7.1. 7632 Martin Lehmköster 28

Requirements for classification � High accuracy � Simple operation –with images � Display of „human classifier“ - high amount of criteria � Easy modification/ high flexibility � Real time ability/ immediately response � Intuitive operation 7.1. 7632 Martin Lehmköster 29

Box-classifier � Only for simple criteria: - area, length, width… � Simple manual definition � Unqualified for complex tasks � Danger of „forgotten“! � Pseudo defects! • Division of defects • according to simple criteria • Very good and stable solution for simple task – should be included in every system as a plain classifier. 7.1. 7632 Martin Lehmköster 30

Today: „Next neighbour“-classification � Self-learning classifier � „Mathematics is hidden“ � Easy modification � Little basic information (Images) necessary � No „over-teaching“ possible � Anytime extendible � Avoiding pseudo-defects A fast learning classifier gives a higher ROI 7.1. 7632 Martin Lehmköster 31

Fast learning classifier! results ? time Get your production run at once with a classifier - do not waste time with teaching a classifier 7.1. 7632 Martin Lehmköster 32

User-friendly learning The user selects a defect out of the continuous production Easy to understand, easy to operate Description Guarantee for quick implementation Saving of information back to data base of system 7.1. 7632 Martin Lehmköster 33

Learning • Requirements … – Classifier needs image gallery – For every defect class images must be available – Images will be collected during production automatically 7.1. 7632 Martin Lehmköster 34

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection 4. Classification – higher ROI 5. DataMining – make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 35

Data Preparation – reducing data to a reasonable extent Defect- database + e-mail list Individual Time table report 7.1. 7632 Martin Lehmköster 36

Example: Single lane report to rate quality 7.1. 7632 Martin Lehmköster 37

central data mining STEP III global network 7.1. 7632 Martin Lehmköster 38

Agenda 1. Introduction to ISRA 2. Reduce costs, increase productivity 3. Basics of web inspection 4. Classification – higher ROI 5. DataMining – make money out of your data 6. Rewind Manager to reduce costs 7. Validation 7.1. 7632 Martin Lehmköster 39

40 7.1. 7632 Martin Lehmköster Marking defects

Winder Interface & Control Main Inspection System Configuration Data Defect Data Rewind Manager Rewind Controls PLC 7.1. 7632 Martin Lehmköster 41

Defect Marking and Web Position Synchronization Start 0 Defect Mark 1 1 (Bottom Side) 0 1 1 0 0 Web Sync Marks 0 (Top Side) 1 ½” 7.1. 7632 Martin Lehmköster 42

Rewind Manager – total system solution Rewind Manager to automatically stop re-reeler for defect removal • Defect marked at defect location on top surface • Codes marked on bottom surface Rewind Manager Sending “slow down” pulse 2000 ft before defect PLC • Mark Reader controls reel map Break Control display to show image and location of next defect to stop on PLC Decode Barcode • Operator override to skip defect 7.1. 7632 Martin Lehmköster 43