no defect material to the customer! smashtm / quality … in no defect to your final customer! 6...

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RRRR No defect material

to the customer!

SMASHTM / Quality-Reviewer

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I will not discuss …

- how to detect a defect …. - which camera is the best to use …. - which light configuration is recommended …. - algorithms for best classification results ….

- I will not talk about granted basics !

I will not discuss about:

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I want to speak about …

I want to speak about the question: - What to do after having found defects ? - How to avoid shipping the defects to customer ? - How to get most value out of inspection data ?

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Beyond Inspection

Tools to get most value out of inspection data: - Reviewer - Data Mining and Reporting - Slit Optimization - Quality Reviewer

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The Web Coating Story

The Web Coating Story is about Outstanding performance in defect detection! Outstanding performance in data handling! Implementation of the inspection data in the production workflow! Making the quality decission process fast and reliable!

Results in no defect to your final customer!

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Jumbo Jumbo Jumbo

Web Product Process We support the complete production chain

Coating line

Insp

ectio

n

Slitt

ing

Prev

iew

Def

ect T

rend

A

larm

ing

Sort

ing

out

Dau

ghte

rRol

l B

lock

ing

Qua

lity

deci

ssio

n

Transfer defect data from Jumbo roll to customer daughter roll

Storage Buffer for Jumbos Slitter

Roll1 Roll2 Roll3 Roll4

Transportation to the customer

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Jumbo

Inspection

While the Jumbo Roll will be produced the SMASH System detect defects !

Insp

ectio

n D

efec

t Tre

nd

Ala

rmin

g

Coating line

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Inspection

The Production Process The speed is too high for the human eyes to see defects The Jumbo roll runs for a certain time The Jumbo roll is more than thousand meters or even several

kilometers long Inside this length can be critical defect: A small fruitfly !!

Don‘t let it become Your customer‘s fruit fly!!

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Inspection

So lets try to find Your fruit fly in the process!

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Review of Inspection

All defects will be displayed in the RealTime Viewer

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Review of Inspection

Also Your fruitfly!

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Inspection

The fruit fly is inside the database, stored with hundreds of other defects. Some of them are relevant, some are not relevant.

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Quality Review

We are still before slitting! The daughter roll with the fruit fly needs to be identified!

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Jumbo Jumbo

Quality Review Now the Jumbo roll is finished and stored.

Slitt

ing

Prev

iew

Dau

ghte

rRol

l B

lock

ing

Qua

lity

deci

ssio

n

Transfer defect data from Jumbo roll to customer daughter roll

Storage Buffer for Jumbos

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Quality Review

The human quality inspector now reviews the Jumbo roll

Indentifying all critical defects

Preventing shipment of defects to customer

Informing the operator at the Slitter

Document the internal quality process

Order spare rolls from the warehouse

Release of quality for shipment

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Quality Review

This will be fully supported with SMASH Load the Jumbo roll

Load the cutting schema (Roll Cut Layout)

Consider material stretch in Downweb and Crossweb

Reviewing the defects

Blocking of the defective daughter roll

Don

e in

5 m

inut

es

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Quality Review

Load your Jumbo roll

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Load the cutting schema Load exsting cutting schema

Create new cutting schema

No limitations in creation of cutting schema.

Consider the stretch in MD and CD in % or mm

Quality Review

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Apply your cutting schema

Stretch Coefficient

Cross Cuts

Length Cuts

Quality Review

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Now the cutting schema is applied to the Jumbo roll!

Cutting schema

Quality Review

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Now we have to find the fruit fly! Quick browsing through the defect images with the Defect Viewer!

Quality Review

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You found the fruit fly! By pressing the button the daughter roll is blocked!

Quality Review

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There is much more the Defect Viewer can do for You! Indicating if the defect is near a cutting position => take out both rolls

Hiding defects of blocked roll

Showing you the sourounding of the defect by 1x1meter

Quality Review

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Indentification whether the defect is near a cutting position!

Defect position near cutting edge. Check neighbour roll as well!

Quality Review

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Showing you the sourounding of the defect by 1x1meter!

Gives you additional information

Quality Review

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Hiding defects of blocked rolls!

Reduce time and effort in reviewing defect data

Quality Review

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Sorting Out We support the complete production chain

Sort

ing

out

Transfer defect data from Jumbo roll to customer daughter roll

Slitter

Roll1 Roll2 Roll3 Roll4

Transportation to the customer

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All defects are verified! The report of the blocked roll will be handed over to the operator at the

slitter.

Sorting out

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Sorting Out

OK

OK

OK

OK

OK

Transportation to Customer

Transfer defect data from Jumbo roll to customer daughter roll

The fruit fly is sorted out!

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All decissions are documented and traceable

The Quality Reviewer Order oriented quality evaluation

Quality view of Multiple Jumbo Rolls belonging to one order

Verifying decissions on one finger tip

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Quality Insurance and Data Handling

Order Number

Blocked Roll

Our fruitfly

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Why SMASH?

No relevant defect reaches your customer!

You avoid complaints and unhappy customers

You fulfill the demands of your customer

Quick and effective quality evaluation

Argumentation and documentation of your internal quality process towards your customers

Prove your quality by giving reports to customer

Pass better the customer audits

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Requirements

SMASH System in the production line

Reviewer

Software “Quality Evaluation"

PC and Network to Inspection System Database

Trained Operator

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Configuration – single installation

Your PC

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Configuration with access to several single lines

Your PC

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Configuration with access to several lines with common database

Your PC

inspection database

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ISRA: Facts and Figures

Established :

Legal Form :

Number of Employees :

Sales 2010/2011 :

R&D Investment :

1985

AG, public company

490

75 Mio. €

11 Mio. €

46% 56%49%

39%19%

52% 11% 7% 8%

33%-15%

12%16%

20

40

60

80

100

120

97/98 98/99 99/00 00/01 01/02 02/03 03/04 04/05 05/06 06/07 07/08* 08/09* 09/10* 10/11*

Revenues in mil €

Datenreihen2

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Subsidiaries: Germany: - Darmstadt (Headquarters), - Aachen, - Berlin, - Herten, - Karlsruhe, - Mainz, - Bielefeld USA - Atlanta, - Bloomfield Hills China - Shanghai, - Tianjin Korea - Seoul Japan - Tokyo Taiwan - Taoyuan India - Mumbai, - Calcutta Brazil - Sao Paulo Turkey - Istanbul

Herten, GER

Shanghai, CN

Atlanta, USA

Worldwide Organization Close to the Customer

Aachen, GER

UK - Hampshire, - London Finland - Helsinki Italy - Rovereto Spain - Barcelona Ruddia - Moscow

Bloomfield Hills, USA

Production : Germany: - Darmstadt, - Herten, USA - Atlanta, China - Shanghai, Turkey - Istanbul

Asia/ ROW

Americas

Europe

Revenue in Regions

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Thanks for your attention!

Questions?