Quality control systems - how to implement them and integrate them effectively with industrial automation

Estimated reading time: approx. 8 minutes

TL;DR

• Quality control systems are key to reducing defects and waste in the production process.
• The latest solutions are often based on integration with robots and AI.
• Implementation requires an audit of processes, equipment selection and staff training.
• Regular maintenance and updates keep the system effective.
• Working with an experienced integrator speeds up implementation and reduces costs.

Table of contents

• Introduction
• What are quality control systems and why are they becoming so important?
• Key elements of modern quality control systems
• Benefits of implementing quality control systems
• Steps for implementing a quality control system in a production facility
• Quality control system and robotisation - a combination that increases productivity
• Most common challenges and mistakes when implementing quality control systems
• Practical tips and conclusions
• Summary
• FAQ

Introduction

Quality control systems are now becoming the cornerstone of production processes in an increasing number of industrial plants. Increasing market demands and the need to meet stringent standards mean that investing in solutions to support quality monitoring is often the only way to remain competitive. This article explains what modern quality control systems are, why they are so important in the manufacturing industry and what their integration with industrial automation looks like.

After reading, you will know where to start the implementation, which technologies to choose and how to avoid the most common mistakes in the implementation process.

What are quality control systems and why are they becoming so important?

Quality control systems (sometimes referred to as automatic inspection systems) are complex solutions that use, among other things, vision technology (cameras), measurement sensors, artificial intelligence or Big Data analytics to continuously monitor product quality parameters during the production process. They operate on two levels:

• They detect defects and flaws, often still at the level of individual components.
• They analyse the causes of possible errors and allow necessary corrections to be made more quickly, resulting in reduced waste and costs.

Interest in quality control systems is growing steadily. This is primarily dictated by:

• Changing regulations and standards (e.g. ISO or industry safety regulations) that enforce close monitoring of quality on the production line.
• Customer pressure for higher quality and lower complaint rates.
• The drive to optimise costs - the automated system allows defects to be detected early and subsequent production steps to be saved.
• Staff shortages that make manual control not only expensive but also inefficient.

At Michale Automatika (often referred to as Michale Automatika), a company specialising in the construction of machinery and production lines, investments in integrated quality control solutions bring clear business results for customers in industries ranging from food and automotive to steel products or electronic devices.

Key elements of modern quality control systems

Vision automation

Vision systems are currently the most popular form of quality control.

• They use industrial cameras (2D or 3D) to capture real-time images of the product.
• The software then analyses the image and compares it to an established template or a specified dimensional tolerance.
• This makes it possible to catch deviations from the norm (scratches, deformations, missing parts) often in fractions of a second, without having to stop the production line.

Data analysis and artificial intelligence (AI)

Some industries, particularly those requiring high precision (e.g. the medical or automotive industries), are enriching vision systems with machine learning algorithms.

• Algorithms learn to recognise not only reproducible defects, but also non-standard anomalies that are difficult to classify by traditional methods.
• In addition, integration with Big Data tools allows the collection of large volumes of information that can be analysed in real time. This makes it possible to predict failures, prevent defects and continuously improve production processes.

Integration with robots and machines

A modern quality control system works best when it is fully integrated with the rest of the production line:

• Robots - including industrial robots or cobots - can automatically deliver parts or semi-finished products to inspection stations.
• The vision systems work in conjunction with the line control modules, allowing a defective component to be rejected immediately and diverted for repairs, for example.
• Integration with automated warehouses or material handling systems allows defective products to be quickly separated before they reach the final stage.

An important aspect is compatibility with ERP/MES systems, which provide information on production progress and key performance indicators. The implementation of such data synthesis greatly facilitates real-time quality control.

Benefits of implementing quality control systems

Investing in quality control systems not only reduces the percentage of shortages and returns, but also clearly increases the efficiency of the entire production.

Prevention of errors and scrapes

One of the main reasons for implementing automated inspection methods is to eliminate errors at an early stage:

• The system identifies the defect almost immediately, which reduces the number of subsequent processes into which the defect would be 'carried'.
• This reduces so-called scrap, which is the material or raw material that has to be discarded.

As a result, the company uses less energy and resources and the production line runs more stably.

Compliance with norms and standards

For industries with stringent quality regulations (e.g. SOPs, health and safety, EU standards or ISO 9001), quality control systems play a key role in:

• Collection and archiving of data on each product - particularly important in pharmaceuticals or the food industry.
• Ensuring full traceability. If an accident or complaint occurs, the batch and individual production processes can be identified in a short period of time.

Confirmation of the efficiency of the quality control system can be provided by audits from customers or independent certification organisations.

Steps for implementing a quality control system in a production facility

In order to effectively integrate quality control systems into your fleet and prevent potential problems, it is worth approaching implementation in a methodical manner.

Audit and definition of requirements

1. Process analysis: It is essential to identify which areas of production are most prone to defects.
2. Identification of critical points: The inspection system focuses on the segments where past errors have been most frequent and costly.
3. Working with an integrator: During the audit, the need for specific types of sensors, cameras or algorithms is determined together with the implementation company (such as Michale Automation).

Implementation and integration

1. Hardware and software selection: Modern quality control systems consist of high-resolution cameras, lighting adapted to specific production conditions and algorithms for analysing the image or measurement data.
2. Integration with existing machines: This is where the experience of the integrator becomes crucial. Care must be taken to ensure that the vision system or other control module does not interfere with the current equipment and lines.
3. Implementation tests: For a period of time, the system is tested in simulation or parallel mode before it becomes a standard process link.

It is worth remembering that when introducing an automated quality control system, the expansion of the line with new robotic stations can be planned at the same time. Examples include automatic packaging or welding stations, which already have integrated sensors and cameras. You can read more about such possibilities in the offers of robotic production workstations.

Training and monitoring

1. Staff training: Even the best quality control system will not work properly if the team does not know how to use it to its full potential. It is therefore crucial to teach operators how to use the control panels, interpret reports and make ongoing modifications.
2. Continuous improvement of settings: Control parameters and permissible error margins should be updated regularly.
3. Maintenance and service: In order to maintain the precision of the controls, regular cleaning of the cameras, inspection of the lighting modules and verification of the software is essential. If you want to learn more about keeping your control stations in impeccable condition, check out Service and maintenance stands.

Quality control system and robotisation - a combination that increases productivity

Quality control systems become even more effective when they interact with industrial robots. Michale Automation is an official distributor of SIASUN robots, which makes it possible to combine state-of-the-art mechatronic solutions with a vision and sensor inspection package in a single project.

With these combined forces, the company receives:

• Fast and repeatable handling of components on production lines - robots relieve workers of monotonous processes and accurately position the workpiece for quality control.
• Better data integration - defect information can feed back in real time from the vision system to the robot's main controller, which, for example, removes incorrect parts or sets them aside for additional verification.
• Scalable - it is easy to automate further areas of production by adding another camera or a new measuring module.

For example, in projects involving the task of packaging and palletising sensitive products, the combination of a SIASUN robot and inspection cameras ensures that only pieces that meet specifications reach the final packaging. If you are interested in automation in a similar area, take a look at our range of products: Robotisation of packaging.

Most common challenges and mistakes when implementing quality control systems

Although modern technology is increasingly simplifying the process of installing automatic inspection systems, pitfalls can still be encountered in practice:

• Inaccurate pre-implementation analysis: Attempting to implement solutions or components (e.g. cameras with inadequate resolution) can lead to erroneous results and false alarms.
• Lack of proper lighting: Light and its appropriate intensity play a key role in vision systems. Even the best camera can fail if the lighting is unstable or spectrally inadequate.
• Skipping updates and maintenance: Quality control systems, especially those with AI elements, require regular updates to models. If corrections are not made over time, detection performance decreases.
• Insufficient operator training: Sometimes management assumes that the machine will 'take care of everything'. Meanwhile, employees have to operate the lines and the system, read reports, rectify minor faults - without this, it is difficult to talk about increasing efficiency.

Practical tips and conclusions

Here is some advice for anyone planning to implement quality control systems:

1. Do an ROI (return on investment) analysis
   Automated quality control systems can be expensive, especially when artificial intelligence is involved. It is therefore worth calculating the potential gains from reducing defects and improving market reputation. If you want to quickly assess the profitability of potential robotic solutions, you can use the ROI calculator for welding robotisation.
2. Don't forget interoperability
   Before buying a new camera or scanner, make sure it can be adapted to the infrastructure you already have (PLCs, MES systems). With a view to possible expansion, choose modular solutions that can be scaled and upgraded in the future.
3. Opt for a partner with experience
   Implementing on your own without the support of an automation systems integrator can be lengthy and risky. Expertise will reduce implementation time and minimise costs associated with implementation errors. For years, Michale Automation has offered a comprehensive approach - from design to installation to service and maintenance, allowing you to plan your line upgrade efficiently.
4. Educate staff and introduce a culture of quality
   It is worth building awareness among employees that the quality control system is a tool for them, not against them. Regular training, clear operating instructions and reinforcing motivation are key to success in the long term.
5. Monitor and develop the system
   Once implemented, a quality control system is not a static solution. Production conditions change, new component suppliers appear, and with them other types of defects. It is therefore worthwhile to carry out optimisation audits, modify parameters and update the software from time to time.

Summary

Quality control systems are a milestone towards modern, fully automated production. They provide instant detection of defects and immediate response, which translates into higher product quality and less waste. As a result, companies gain not only in terms of image, but above all economically - reducing waste, streamlining processes and increasing production safety.

If you are thinking about implementing modern inspection technologies, bear in mind:

• A thorough pre-audit and identification of critical quality points.
• Selecting the optimum technology for production conditions (appropriate cameras, lighting, AI algorithms).
• Professional integration with other elements of the machine park (robots, packaging robotisation, ERP/MES systems).
• Systematic staff training, equipment health checks and software updates.

Are you considering improving your quality control with a multifunctional vision station or integration with SIASUN robots? The Michale Automation team has years of experience in the industry and, as an official distributor of SIASUN actuators and robots, can offer a comprehensive and tailored solution. Contact us or visit our services department to find out how we can implement state-of-the-art quality control systems specifically for your industry: Explore our range of services.

Remember that an investment in modern quality control will pay for itself many times over - not only by reducing the costs of poor production, but also by increasing the satisfaction of your customers and building a strong market position. Opt for quality control systems integrated with industrial automation and enter the world of intelligent production.

FAQ

How do you select the right vision cameras for your quality control system?
The choice of cameras depends on the specific product and line conditions (e.g. lighting, belt speed). Typically, high-resolution industrial cameras are relied upon, supported by additional lenses or filters if necessary.

Does the integration of a quality control system require production to stop?
Full integration may require short downtimes, but an experienced integrator can minimise these to the minimum necessary. In addition, many tests are carried out in simulation mode.

How quickly does the investment in a quality control system pay off?
The payback time depends on the industry, the scale of production and the type of defects so far in the process. In many cases, ROI occurs within several months due to a significant reduction in the cost of defects and complaints.