Mistake-proof your production process with

POKA YOKE CAMERA

All-in-one unit. No PC required. Result and Image log.

Increase Productivity. Increase Accuracy. Increase Safety.

We assist the workflow of your industry using vision technologies. Learn more from us.

Follow us on Linkedin.

Introduction Price

USD 2,498

SODA VISION PTE LTD

39, Woodlands Close, #05-61, MEGA @ Woodlands,

Singapore 737856

T: (+65) 6694 0389

sales@sodavision.com www.sodavision.com

POKA YOKE CAMERA Assist workers in all work scenarios

INSPECTION PACKAGING PICKING ASSEMBLY

ASSEMBLY CHECK

EASY INTEGRATION

COLOR CHECK TEXTURE CHECK CHARACTER CHECK

EASY DEPLOYMENT

We assist the workflow of your industry using vision technologies. Learn more from us.

RICOH SC-10A automatically

checks similar part, incorrect

part, work instruction and other assembly condition

during the work process by

pattern matching.

The data can be used for

work analysis and traceability

by recording the work result images and the result such

as serial number and work

time.

Poka Yoke CameraSC-10AIntroduction

2

・Overview

・Target

・Difference with general smart camera

・Conventional solution

・Specification

・Case-study

Agenda

3

Factory automation and Human work

Factory automation will expand more and more. 2022

Market size forecast 7 trillion yen

2015年 2016年 2017年 2018年 2022年予測

Process done by human will be remained.

Human error is come along.

The SC - 10A digitizes visual checks

“Human error is decreased"

4

SC-10A Overview

Monitoring human work

ALL IN ONE and Easy operation IoT Traceability

Management of work instruction

Work ID Work No Worker ID Work Work Item Date TimeElapsedTime

ProcessItem

ResultImage LogFile Name

S/N

Model_A Serial_B Worker C Input Order Scan Order Sheet 2016/6/10 10:12:14 2 S/N OK A051xxxxModel_A Serial_B Worker C Assemble Unit A Set Lens 2016/6/10 10:12:17 3 Matching OKModel_A Serial_B Worker C Assemble Unit A Scan PCB 2016/6/10 10:12:20 3 S/N OK C142xxxxModel_A Serial_B Worker C Assemble Unit A Set PCB 2016/6/10 10:12:32 12 Matching OKModel_A Serial_B Worker C Assemble Unit A Check Cable 2016/6/10 10:12:36 4 Matching OKModel_A Serial_B Worker C Assemble Unit A Set Cable 2016/6/10 10:13:26 50 Matching OKModel_A Serial_B Worker C Assemble Unit B Check Wheel 2016/6/10 10:13:30 4 Matching OKModel_A Serial_B Worker C Assemble Unit B Set Wheel 2016/6/10 10:13:41 11 Matching OKModel_A Serial_B Worker C Assemble Main Unit Set Case 2016/6/10 10:13:57 16 Matching OKModel_A Serial_B Worker C Assemble Main Unit Fasten Case 2016/6/10 10:14:05 8 Matching OK Assemble.jpgModel_A Serial_B Worker C Assemble Main Unit Scan Label 2016/6/10 10:14:08 3 S/N OK A051xxxxModel_A Serial_B Worker C Assemble Main Unit Put Label 2016/6/10 10:14:14 6 Matching OKModel_A Serial_B Worker C Inspection Function Test 2016/6/10 10:14:35 21 Check OKModel_A Serial_B Worker C Inspection Appearance Check 2016/6/10 10:14:45 10 Check OK Inspection.jpgModel_A Serial_B Worker C Packing Set Packing Box 2016/6/10 10:14:53 8 Matching OKModel_A Serial_B Worker C Packing Bundle Manual 2016/6/10 10:14:56 3 Matching OKModel_A Serial_B Worker C Packing Bundle CD 2016/6/10 10:14:59 3 Matching OKModel_A Serial_B Worker C Packing Packing Product 2016/6/10 10:15:09 10 Matching OKModel_A Serial_B Worker C Packing Put Packing Label 2016/6/10 10:15:14 5 Matching OK A051xxxxModel_A Serial_B Worker C Shipment Shipment 2016/6/10 10:15:27 13 Check OK Shipment.jpg

5

Target

Conventional smart camera

・Continue to perform a single inspection

SC-10A・Check multiple work steps

・Manage its work procedures.

6

- Concept is different from conventional smart camera. Common smart

cameras will be a single continuous examination in a row.

→ detection when a defect occurs.

Human error itself can not be prevented.

SC-10A has a mechanism that does not make defects by monitoring process

steps rather than inspection.

Prevent the occurrence of human error!

Difference with conventional smart camera

Conventional Solutions – “digital cell”

Footswitch

Control of electric

screwdriver

Work instructions displayed

on screen monitor (videos,

drawings, etc.)

Error warning by light

Digital Picking

System

Built-in sensor detects where to take the part.

Poka-yoke (prevent human error mistakes) in “digital cells”

by a combination of electrical check results and job instructions.

Industrial PC

Setback

• Expensive (10K euro/cell)

• Dedicated engineers are needed.

(Self-made or custom-made.)

• System construction is difficult. (Especially wiring)

• Only electric screwdrivers and picking available

• No trustful record (only check sheet)

SC10-A solves !Write check sheet

8

Effect of changes in production sites

Mass production = short tact time

Repeat simple task

small lot production of many products =long

tact time

Complex work, multitasking.

Conventional factory Current factory

Simple mistake "Pocamis" frequently occurred! □ Mistakes also occurred from processes that have not yet come

up! □ Market leakage of defective items

Influence

□ Increase in inspection process □ Increase in overtime due to rework □ Pursuing causes of defects Generation

of costs

Decreasing Human error lead productivity improvement!

9

Mechanism which is reducing human error

1. Mechanism that can not making mistake

◆ Eliminate mistakes

◆ Remove factors causing work mistakes

◆ Eliminate people's judgment

2.Detecting mistakes when error occurred

◆ Make it clear that you made a mistake

◆ Not to proceed if there is a mistake

◆ Add inspection process

3. Mechanism that makes mistakes difficult◆ Educate ways to make mistakes difficult

◆ Process placement at the right place

◆ Make the contents of work easier to understand

◆ Calling attention before a mistake happens

◆ Have a moderate tension

高架化

遮断機付きの踏み切り

警報機・踏切警標

helps greatly to eradicate

human error

Ricoh's originated camera

system

10

Since it must pass the image recognition to go to the next step, preventing human error is difficult.

Monitoring human work

· Prevent defects beforehand!

· prevent defective products from leaving the factory

Correct

Work result

Real time work

OK

NG

Continue work according to

work instructions and do

work until it is in the correct

state.

Display alerts after a certain

period of time

· Visual check process is unnecessary!

· Contributing to process reduction

Method：Compare with master image(correct work result) with real time image.

⇒Determine if the real-time image matches the master images.

11

Difficult to recognize by

pattern matching and color

recognition…

※ex The cases of black

colored objects

different colors in a same form

can be identifiable.

Image recognition method

Identify parts

Check the assembling

①Pattern matching ②Color recognition

It discriminates from a similar part

by color recognition.

③Texture recognition

① presence or absence of parts

② Identify whether parts of the

correct shape are attached

By using 3 methods, it is possible to recognize various objects!

12

Contribute to quality improvement

In the examination that

relied on visual

inspection, there are

error range.

Precision decreases

with the decrease in

concentration.

Camera inspection

has a fixed standard.

Since concentration

does not matter, the

inspection result will

be constant.

SC-10A also contributes to improving product quality!

13

Simple and easy setting

Setting③：The point you want to check

is just click and drag with the mouse.

Setting①Capturing the master image is

Just clicking the capture button.

Setting②：Setting the anchor point

Just click and drag with the mouse.

※The check point is judged by the distance from the anchor point.

You can set easily and check various point and various objects!

14

Management of work instruction ①

Proper work method · Process work leads to stable quality and shortest lead time production.

Merit

· Easily capture the procedure manual you created and display it on the monitor.

· Since the work you want to check can be set by the customer, it can be used for various work process.

· Process abnormality can be detected.

work procedure is displayed on the monitor.

recognizing the result is OK, the procedure manual will proceed

next page.

15

Management of work instruction ②

Issue: To prevent careless mistakes, man-hours for parts feeding, self-check, and double-check are

required.

Worker1

Parts

FeedingAssembly Self-check

Double-

checkAssembly Self-check

Worker2

Function

Test

Visual

InspectionShipment

Worker3

■Normal Assembly Procedure

Worker1

Parts

FeedingAssembly Self-check

Double-

checkAssembly Self-check

Worker2

Function

Test

Visual

InspectionShipment

Worker3

Since the SC-10A automatically checks for careless mistakes during the assembly,

the quality can be maintained while the man-hour is reduced.

No Need No Need No Need No Need

■Solution by RINS Camera

Quality is maintained in each production

process.

16

Iot Traceability

Operation log can be used as actual collection function.

Useful for product traceability.

Use process change and rearrangement based on work results help to improve production efficiency.

It helps to reduce man-hour by automatic check and improve quality.

Paper operating procedure, check sheet

↓

Digitization

Visual inspection

↓

Image recognization

Work ID Work No Worker ID Work Work Item Date TimeElapsedTime

ProcessItem

ResultImage LogFile Name

S/N

Model_A Serial_B Worker C Input Order Scan Order Sheet 2016/6/10 10:12:14 2 S/N OK A051xxxxModel_A Serial_B Worker C Assemble Unit A Set Lens 2016/6/10 10:12:17 3 Matching OKModel_A Serial_B Worker C Assemble Unit A Scan PCB 2016/6/10 10:12:20 3 S/N OK C142xxxxModel_A Serial_B Worker C Assemble Unit A Set PCB 2016/6/10 10:12:32 12 Matching OKModel_A Serial_B Worker C Assemble Unit A Check Cable 2016/6/10 10:12:36 4 Matching OKModel_A Serial_B Worker C Assemble Unit A Set Cable 2016/6/10 10:13:26 50 Matching OKModel_A Serial_B Worker C Assemble Unit B Check Wheel 2016/6/10 10:13:30 4 Matching OKModel_A Serial_B Worker C Assemble Unit B Set Wheel 2016/6/10 10:13:41 11 Matching OKModel_A Serial_B Worker C Assemble Main Unit Set Case 2016/6/10 10:13:57 16 Matching OKModel_A Serial_B Worker C Assemble Main Unit Fasten Case 2016/6/10 10:14:05 8 Matching OK Assemble.jpgModel_A Serial_B Worker C Assemble Main Unit Scan Label 2016/6/10 10:14:08 3 S/N OK A051xxxxModel_A Serial_B Worker C Assemble Main Unit Put Label 2016/6/10 10:14:14 6 Matching OKModel_A Serial_B Worker C Inspection Function Test 2016/6/10 10:14:35 21 Check OKModel_A Serial_B Worker C Inspection Appearance Check 2016/6/10 10:14:45 10 Check OK Inspection.jpgModel_A Serial_B Worker C Packing Set Packing Box 2016/6/10 10:14:53 8 Matching OKModel_A Serial_B Worker C Packing Bundle Manual 2016/6/10 10:14:56 3 Matching OKModel_A Serial_B Worker C Packing Bundle CD 2016/6/10 10:14:59 3 Matching OKModel_A Serial_B Worker C Packing Packing Product 2016/6/10 10:15:09 10 Matching OKModel_A Serial_B Worker C Packing Put Packing Label 2016/6/10 10:15:14 5 Matching OK A051xxxxModel_A Serial_B Worker C Shipment Shipment 2016/6/10 10:15:27 13 Check OK Shipment.jpg

Work results can be

saved as images

Operation log can be used as

actual collection function.

S/N for important parts can be recorded

17

External I/O Function

Cooperated with

Electric ScrewdriversExpansion of

External EquipmentInstalled in the assembly

line.

(PLC Control)

Adding the external I/O function allows the system to cooperate with external equipment, and

checking other than image recognition becomes available.

Also, PLC control becomes available if it is installed in the production line.

Controller

Power ON →

[Output] Power is supplied only to the target screwdriver.

[Input] Check if the screw is completely tightened.

← Screw is completely tightened.

Relay

Solenoid

Signal Light Tower

Sensor

Footswitch

USB

Memory

HDMI Monitor

HDMI Cable

USB Hub

USB

MouseUSB Keyboard

External Cable

E,g, PLC

USB Cable

Cumer

AutomobileHome

appliances

Medical home

appliances Chips for audio

Target industry

18/04/2019 Version: [###] Classification: Internal Owner: [Insert name] 18

Customers voice:

Assembly mistakes

have been reduced

and quality raised.

19

Case-study①

20

Case-study②

CH

AL

LE

NG

E Defective products through wrong work

sequences and missing parts at assembly

process.Worker checks own work results

leading to defects.

For assembly production the customer aims

to decrease error rates at as low cost and

easy as possible. New staff should be able to

work in full capacity in as short of time as

possible.

Defective parts and assembled parts are

checked by image recognition before going

over to the next task. Poka-yoke (defect

through human errors) is eliminated.

Digital work results led to improvements in

operations and costs.

CU

ST

OM

ER

Large-scale company, worldwide renowned

producing hoses for air conditioners, brakes,

etc. for automobile and motocycle industry as

well as for housing facilities.

21

Case Study ③

CH

AL

LE

NG

E Defective products through wrong work

sequences and missing parts at assembly

process. Worker had to input barcode and

identification data manually, which led to

errors.

Customer wanted a system, which could

work with small and medium sized objects.

Customer wanted to decrease identification

of product data by manual input. Barcode and

RFID identification was introduced and used

for automated job sequencing. Texture and

color recognition was used.

Poka-yoke (defect through human errors) is

eliminated. Production flow optimized.

CU

ST

OM

ER Company producing precision parts products,

the main product being a plastic fastener for

industrial use.

SODA VISION PTE LTD39, Woodlands Close, #05-61, MEGA @ Woodlands, Singapore 737856

(+65) 6694 0389www.sodavision.comsales@sodavision.com