Product control in modern production: the key to quality and efficiency

Estimated reading time: approx. 8 minutes

TL;DR

• Product control helps maintain quality and repeatability of production.
• Lack of proper control increases costs and the risk of complaints.
• Vision systems, sensors and robots streamline the verification process.
• Integration of controls with MES/ERP systems speeds up the response to irregularities.
• Robotisation and automation allow a high return on investment to be achieved.

Table of contents

• Introduction
• Main content
• Why is product control so important?
• Major challenges in product control
• What technologies support product control?
• Integration of product control into production processes
• Practical examples of product control implementation at Michale Automatics
• How do you choose the right control solution?
• Step-by-step implementation of solutions
• Internal linking - additional sources of knowledge
• Summary - key findings and recommendations
• FAQ

Introduction

Product control is the cornerstone of effective production - without it, it is easy for quality shortfalls, material losses and even a loss of competitiveness for the entire company. Today's customers expect ever-higher standards, and companies strive to ensure that their products fully comply with strict industry, legal and social standards. But does product inspection always require costly and time-consuming procedures? In the following article, we will show how, thanks to modern solutions (machine vision, robotics, automation), quality control can be significantly improved and ultimately increase the profitability of the entire plant.

This article was prepared by Michale Automation, which specialises in the construction of machines and production lines, the integration of industrial automation systems and the implementation of robotic workstations in companies of all sizes. With years of experience in the field of automation and robotics, we can show how product control can be optimised for cost efficiency, increased quality and safety.

Main content

Why is product control so important?

Product control is a method by which companies ensure the repeatability of products, compliance with standards and minimise defects and complaints. This is particularly important in industries where an error or quality deviation can result in a risk to consumer health and safety (e.g. the food or pharmaceutical sectors).

Impact on image and competitiveness

In the age of the instantaneous spread of information on social media and online forums, even a single production error can gain enormous publicity. Negative opinions published by existing customers not only affect sales results in the short term, but also have a lasting impact on brand image. Good product control can therefore protect against a PR crisis and loss of customer confidence.

Costs of no control

In addition, it must be remembered that lack of or insufficient product control generates costs associated with:

• Production downtime resulting from repairs and complaints.
• The need to reuse materials or recycle defective intermediates.
• Reduced logistical efficiency as a result of a longer operational process.

For this reason, a well-designed verification system, especially one supported by the latest technologies, is a viable investment with a rapid return (ROI).

Major challenges in product control

While product control is crucial, many companies face issues that hinder the effective implementation of comprehensive quality procedures.

Variety of product range

Companies often offer a wide range of products, with different shapes, dimensions and technological specifications. This complicates the inspection process considerably - each additional criterion usually means another measurement or test procedure.

Shortage of skilled workers

In an era of staff shortages, some companies find it difficult to fill quality control positions. As a result, qualified inspectors have to oversee multiple processes simultaneously, increasing the risk of human error.

High requirements of market regulators

Industries such as food, pharmaceuticals or automotive are subject to numerous regulations. Any significant discrepancy in documentation or the inability to identify a defective product batch exposes the company to severe penalties and the suspension of sales.

What technologies support product control?

Fortunately, developments in industrial automation are providing an ever-increasing range of possibilities. Advanced vision systems, sensors, cameras or collaborative robots (cobots) are now available in a variety of variants, allowing control modules to be tailored precisely to the specifics of production.

Vision systems

Vision systems are based on cameras and image processing algorithms. Their main advantage is their ability to pick up defects that are invisible or difficult to detect quickly by humans. Examples:

• Leakage control of packaging, e.g. in the food industry.
• Verifying the correctness of component assembly in the electronics industry.
• Checking colour shade and paint surface in the automotive industry.

Special sensors (tactile, laser, ultrasonic)

The sensors generate data to track the dimensions, shapes or weights of products in real time. With them you can:

• Detect dimensional deviations on the assembly line.
• Measure the density of raw materials (e.g. in the case of bulk materials).
• Test the correctness of terminals, e.g. in the HVAC industry.

Industrial and collaborative robots (cobots)

Modern companies are increasingly opting for robots to handle not only strictly production processes, but also inspection procedures. A robot equipped with a vision system can perform an inspection sequence with millimetre precision and its work is repeatable 24 hours a day. What's more, cobots are designed to be able to interact safely with humans. They then act as the operator's 'hands' for tasks that are difficult to complete in manual mode.

Integration of product control into production processes

Implementing automated quality control is not just a matter of buying the right camera or sensor. Equally important is the integration with already existing systems: PLC, SCADA, and increasingly also with ERP software (e.g. for enterprise resource management) or MES (Manufacturing Execution System).

Data collection and analysis

Real-time data collection allows for early detection of anomalies and rapid response to potential defects. For example, if the vision sensor picks up that a batch has been misfitted, the MES system will automatically respond by sending an alert to the operators and stopping further processing of that batch.

Reporting and documentation

Automatic product inspection often gives access to detailed reports. With these, the company is able to prove the durability and quality of its products when dealing with auditors, customers or inspection bodies.

Practical examples of product control implementation at Michale Automatics

Michale Automation has been combining robotics with the latest in vision systems for years. As an official distributor of SIASUN robots we can offer robotised lines that are not only suitable for welding or painting, but also for automatic inspection and product sorting.

Automatic dimensional verification

For one of our customers in the metal industry, we implemented a station with a SIASUN SR25A robot. The task of this machine was to check the dimensions of workpieces of different shapes and sizes. Thanks to a vision system and a precision gripper, the robot:

• It read data from laser sensors.
• He compared them with the tolerances allowed.
• He discarded defective components into separate bins.

This type of implementation has significantly reduced the number of complaints, while speeding up overall production.

Improved welding control

In the automotive industry, on the other hand, the customer was looking for a solution to inspect weld seams (some of which were very difficult to observe with the human eye). Thanks to the integrated welding and thermal camera inspection system, the line was able to detect areas of underheated welds in real time. This automatic fault indication minimised downtime and the risk of subsequent failure of the final product.

How do you choose the right control solution?

Adapting control modules to your own line requires an analysis of the industry, the type of products and the environmental conditions (e.g. temperature, humidity). Here are the most important points to consider when planning:

1. Type of defects to be detected: are they deviations in size, colour, tightness?
2. Production volume and line speed: do we need a high-frequency video recording system?
3. IT infrastructure: does the company have an MES or ERP system with which new modules can be easily integrated?
4. Budget and expected return on investment (ROI): what costs - including training, service and maintenance - are we able to bear?

Step-by-step implementation of solutions

The process of implementing product control itself can be done in several stages, depending on the complexity of the project.

First stage - Needs analysis and consultation

We first determine the quality requirements, the type of products, the availability of space and human resources. At this point, it is useful to contact automation experts to define the initial scope of the project.

Stage two - design and pre-testing

At this stage, a system of sensors, robots and possible vision systems is designed. A prototype is created to test the performance of the solutions under real conditions. If a company is considering robotic welding as part of the process, doubts can be allayed with an ROI simulation (we encourage you to use the online tool: Find out how to calculate the ROI of robotic welding).

Stage three - proper implementation and training

Once the prototype has been approved and any modifications carried out, we move on to installation on the target production line. At the same time, training of the team takes place so that employees are proficient in the use of the new tool, are familiar with basic maintenance operations and are able to interpret the results.

Stage four - monitoring and development

Implementing solutions that automate and robotise product control is not a one-off activity. It is crucial to observe the effects on an ongoing basis, analyse reports and gradually improve the entire system.

Internal linking - additional sources of knowledge

If you are considering introducing robotics for automated product inspection and would like to see the detailed capabilities of today's industrial robots, visit
our automation and robotics servicesAlso see examples of implementations within
robotisation of packaging and
robotic grinding. High precision control is achieved
Siasun SR25A robot, often used in processes where accuracy and repeatability are important.

Summary - key findings and recommendations

- Product control is an integral part of maintaining quality and production safety - on the one hand, it prevents complaint costs and promotes a positive corporate image, on the other hand, it fulfils legal requirements and industry standards.
- Challenges related to product range diversity, staff shortages or strict market regulations can be overcome through the integration of innovative automation and robotics systems.
- The latest solutions - including vision systems, specialised sensors or collaborative robots - make it possible to significantly improve product inspection processes and document product quality.
- The implementation of automated control should always be preceded by an in-depth needs analysis, pre-testing and a refined training plan.
- Robotisation of the inspection process results in higher productivity, more repeatable measurements and, often most importantly, a rapid return on investment (ROI).

We encourage you to find out for yourself what areas of your business can be improved and gain in quality with the right automated product inspection. If you have any doubts about the choice of equipment or the cost of your investment - contact Michale Automatika.

Product control has now become a priority for companies seeking to maintain the highest standards of quality and consistency in production. Fortunately, modern technology - including, in particular, automation and robotisation tools - makes it possible to significantly shorten and simplify this process, translating directly into better financial results.

If you would like to find out more, we invite you to read other articles on the Michale Automation blog and take advantage of our offer, which includes the design and construction of robotic production lines, the implementation of vision systems and a bench maintenance service, among others. Also share your experiences in the comments or subscribe to our newsletter to keep up to date with news from the world of industrial automation and robotics.

Thank you for reading. We hope that this article has helped you understand how important product control can be in today's manufacturing world and the many benefits of automating this key stage. Feel free to get in touch and discuss!

FAQ

How long does it take to implement automation in a company?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simple solutions to several months for extensive projects and large integrations.

Does automation mean redundancies?
Usually no. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies use this to retrain and develop their team professionally.

Does robotisation only pay off for large companies?
Today, advances in technology are leading more and more small and medium-sized companies to turn to robotisation. Costs are coming down and flexible solutions can deliver a favourable return on investment even for smaller operations.