Computer Vision in Manufacturing

Introduction

In today’s ever-evolving industrial world, manufacturers are always on the lookout for better ways to do things. They’re not just trying to keep up with the times; they’re aiming to be ahead of the curve. Leading this charge is a wave of new tech that’s changing the way we think about manufacturing.

As manufacturers seek more accuracy and efficiency, turning toward AI innovations is becoming a notable trend. Computer vision in manufacturing is especially garnering a lot of interest. Just like how our eyes send information to our brains to understand what we’re seeing, computer vision helps machines understand what they are seeing by analyzing images or videos.

The adoption and acceptance of computer vision show a significant shift in manufacturing technology trends toward a more data-driven, automated, and intelligent operational framework, announcing the fourth industrial revolution. This article explores the excitement around vision systems in production, the potential applications of computer vision in manufacturing, and gathers expert opinions on computer vision and what the future holds.

Computer Vision and Machine Learning in Manufacturing

Thanks to advancements in GPU software and AI optimization, computer vision and machine learning are working hand in hand, encouraging high-performance computing in manufacturing - particularly in the realms of inspection, automation, and real-time monitoring. The impressive growth of the global computer vision market, valued at USD 14.10 billion in 2022 and expected to grow at a CAGR of 19.6% from 2023 to 2030, alongside the anticipated value of the machine learning market reaching $158.80 billion in 2023, up from $72.17 billion in 2022, highlights the increasing investments and confidence in these technologies. This fusion is enabling more sophisticated vision systems in production, which are crucial for ensuring quality and safety and for facilitating efficient defect detection and inspection processes.

The merging of computer vision with machine learning opens a world of possibilities. As these tech areas overlap, manufacturers get a unique chance to tap into their combined power. This blend is creating smart manufacturing systems that adjust and fine-tune on-the-go, using live data. It also introduces predictive tools, helping businesses anticipate issues, schedule upkeep, and prevent problems early on. With these advanced tools, manufacturers can not only perfect their operations but also keep pushing the boundaries of what’s possible. This new approach to making decisions with data is changing the game, setting the stage for a future where quick adjustments, accuracy, and planning ahead are standard practice.

Let’s dive into the various applications of computer vision that are significantly changing operational practices in manufacturing.

Applications of Computer Vision in Manufacturing

By capitalizing on computer vision in manufacturing, manufacturers are able to automate many processes. By analysing visual data captured from the manufacturing floor, computer vision systems can accurately identify and track objects, monitor workflow, and detect anomalies such as equipment malfunctions or product defects. For instance, during quality inspection, computer vision can be used to identify surface flaws or measure dimensional accuracy, which in turn leads to fewer quality issues, less rework, and reducing time spent on unnecessary inspections by front-line workers. In assembly lines, computer vision can be used to automate quality control checks, ensuring that each product meets the required standards before proceeding to the next phase of production.

With respect to process optimization, computer vision and machine learning can help with dynamic adjustments to the manufacturing process based on feedback. For example, cameras and IoT (Internet of Things) devices employed in factory synchronization and dynamic scheduling track material and product movement in real-time, which is synced back to other manufacturing systems like ERP (Enterprise Resource Planning) and MES ( Manufacturing Execution System) to dynamically schedule and allocate resources. This leads to improved agility, reduced inventory, and higher Overall Equipment Effectiveness (OEE)​​. The adjustment of machine settings can be automated to optimize production output and reduce waste. Similarly, in inventory management, camera streams can be analysed to detect empty containers and improve restocking procedures, ensuring a smooth flow of materials and minimizing downtime. A great case study of this is a global manufacturer with over 60 locations in 18 countries that utilized custom computer vision models to complete bi-monthly cycle counts of more than 38,000 pallets across the U.S​​. Another example is the use of Oracle’s OCI Vision to automate inventory management efforts using drones or other robots to observe, count, and report information reliably and faster​​.

Expert Opinions on Computer Vision in Manufacturing

Expert opinions on computer vision in manufacturing vary, reflecting a spectrum of perspectives within the industry. On one hand, there’s strong optimism about its potential to significantly transform manufacturing processes, improving automation, precision, efficiency, quality control, and productivity while reducing errors. Eric Danziger, the CEO of Invisible AI, feels that computer vision has immediate applicability and tangible benefits in manufacturing. He elaborates that unlike in other fields, the manufacturing sector can immediately reap significant rewards from computer vision technology, especially in crucial areas like defect monitoring and real-time feedback, which are integral for enhancing product quality and operation.

However, caution is also voiced by experts who highlight the challenges of implementing computer vision in manufacturing. They acknowledge the benefits but stress its complexity, resource-intensive nature, high initial costs, the need for specialized talent, and potential disruptions during the transition phase. Alessandro Gasparini, Executive VP and Chief Commercial Officer at Immervision, discusses the challenge of creating vision systems ahead of market readiness. Immervision specializes in wide-angle optics, sensor fusion, and image processing. They provide lens components to enhance vision solutions. Clients often seek clarity on the broader application of these components. This emphasizes the need for clear use cases to drive adoption. Many experts suggest a balanced approach, addressing immediate needs while planning for digital transformation.

Experts also delve into computer vision’s impact on the workforce within manufacturing. While some express concerns about job displacement due to increased automation, others see it as a way to bolster human capabilities. Christian Lundbak, Head of BPO/BUIT at DHL Denmark, and Mark Bishop, Head of Client Success at Protex AI, emphasize the potential of computer vision in enhancing workplace safety. Lundbak mentions that minimizing risks is data-driven, aiming to prevent accidents before they occur. Similarly, Bishop describes Protex AI’s solution as providing a continuous view of sites to identify risks, showcasing a proactive approach to safety. These perspectives underscore computer vision’s role in preserving jobs and fostering a safer and more efficient work environment. The evolving nature of these technologies accentuates the importance of staying updated to maintain a competitive edge, with a balanced approach being advocated to effectively integrate computer vision in manufacturing, aligning immediate advantages with long-term strategic goals.

Quality and Safety Solutions through Vision Systems in Production

Vision systems in production are becoming integral to enhancing quality and safety solutions in manufacturing. By using the latest advancements in computer vision, these systems are not only improving quality control measures but also introducing strong safety protocols.

One of the key advantages of incorporating vision systems in production is the noticeable improvement in product quality. Machine vision-based quality inspection systems greatly reduce human errors often found with visual inspection tasks. This leads to a significant boost in overall product quality. For instance, in the aerospace industry, machine vision cameras are employed for careful inspection of assembled heads-up displays (HUDs), ensuring they meet the stringent quality standards requisite in such high-stakes sectors​​.

Another good example of the impact of autonomous machine vision systems can be seen in a case study with the BSH Home Appliance Group. This system helped significantly reduce material waste by identifying defects early in the production process. Not only did this improve accuracy in quality control, but it also helped cut costs and was better for the environment. This real-world example clearly shows the substantial benefits of using computer vision in assembly and quality assurance processes​.

The flexibility of vision systems in production is shown by how they’re used across many different industries for quality control during production. This wide range of use highlights the big potential vision systems have to change quality and safety solutions in manufacturing for the better​​.

Furthermore, the integration of vision systems is not just about improving the end product but also about ensuring a safer environment for workers. In manufacturing settings where manual inspection might present dangers, such as interacting with fast-moving machinery or handling sharp objects, automated vision systems can step in. This eliminates the need for workers to be in proximity to certain high-risk operations. For instance, in the automotive manufacturing sector, where precision is crucial, machine vision can oversee the alignment and fitting of parts, ensuring accuracy without human intervention.

In addition to machine vision, the significance of Personal Protective Equipment (PPE) cannot be downplayed. PPE, which includes items like safety helmets, earplugs, and protective footwear, serves as a frontline defense against various workplace hazards. With the integration of computer vision, there’s an added layer of safety assurance. These systems can be set up to monitor workers and ensure that they are wearing the required PPE correctly. If a worker is detected without the necessary protective gear, alerts can be triggered, prompting immediate corrective action. Periodic training sessions are also essential, ensuring that all staff members know how to properly use and care for their safety equipment. In this way, the combination of machine vision technology and traditional safety measures like PPE offers a comprehensive approach to safeguarding workers in the manufacturing environment.

Challenges in Implementing Computer Vision

Implementing computer vision in manufacturing is an essential move towards advancing manufacturing technology trends, but it comes with its set of challenges. The process can be costly and complex, requiring a significant investment in both technology and expertise. Without proper preparation, manufacturers might face considerable hurdles that could hamper the successful integration of computer vision technologies​​. Moreover, scaling CV models to meet manufacturing demands presents another challenge. It’s not just about creating a functioning model but deploying it effectively in a real-world manufacturing setting.

The quality and availability of data stand as major hurdles in this journey. The task of collecting and accurately annotating high-quality data, crucial for training robust computer vision models, often proves to be demanding. This, along with other data-related challenges such as algorithm implementation, data pre-processing, and benchmarking, underlines the critical role of data in computer vision implementation​​.

Future of Manufacturing with Computer Vision

The future of manufacturing with computer vision is evolving alongside digital transformation, which is paving the way for the rise of smart factories. As manufacturing technology trends continue to grow, they’re expanding the scope and applications of computer vision. For instance, the emergence of industrial 3D object detection in 2023 highlights the ongoing evolution of computer vision technologies. These advancements are part of a larger trend of high-performance computing in manufacturing and AI optimization.

The collaborative efforts between tech providers, manufacturers, and other stakeholders are also accelerating the adoption and innovation in computer vision technologies. Through collaborative research, development, and standard-setting, the industry is working towards overcoming the challenges and maximizing the benefits of computer vision in manufacturing.

Looking ahead, the future of manufacturing with computer vision appears bright. As technology continues to advance and the industry adapts to the digital transformation, the applications and benefits of computer vision in manufacturing are bound to expand further. This progression is not only promising for manufacturers but also for the broader economy as it paves the way for more efficient, innovative, and sustainable manufacturing practices.

Conclusion

We’ve explored the impact that computer vision in manufacturing has created, and it is evident that computer vision in manufacturing is not just a passing trend. As computer vision technologies become more sophisticated, they will unlock further potential for innovation in manufacturing, from creating smarter robotics to developing more personalized production techniques.

For manufacturers who are still hesitant about adopting this technology, it’s crucial to recognize that the future of manufacturing will undoubtedly be digital. Those who invest early and strategically in computer vision will be better positioned to capitalize on its benefits, ensuring a competitive edge in a rapidly evolving market.

Computer vision represents a wonderful opportunity for manufacturers to not only streamline their operations but to also reimagine the boundaries of what’s possible in the realm of modern production. As the digital era progresses, the integration of such technologies will be indispensable for manufacturers aiming to remain at the forefront of their industry.

At TechnoLynx, we are extremely proud to have several computer vision experts as valuable members of our team! Within our consultancy services, we use PyTorch and TensorFlow to solve computer vision problems as commonly used deep learning frameworks for developing and training neural networks. See the full scope of our services in Computer Vision as well as the benefits and methods of application in various industries.

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Sources for the images:

• Chooch. (n.d.). Save Lives and Lower Costs—PPE Detection with Computer Vision AI.
• Jones, M. (2020). Computer vision — three exciting ways it’s changing business. Techwire Asia.
• Radiant Vision Systems, LLC. (2021). Quality Considerations for Aviation Head-up Displays (HUDs). Aviation today.