Omron and InduSoft Web Studio Vision Systems
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Omron and InduSoft Web Studio Vision Systems

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Omron uses InduSoft Web Studio for cutting-edge vision systems

Omron uses InduSoft Web Studio for cutting-edge vision systems

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  • Omron InduSoft uses local and remote deployment… Bringing all of the Automation Equipment data… Into one or more Runtime PCs or Servers – running Omron InduSoft Then branching out remotely to what are called “Thin Clients” (not actually managing the SCADA interface and database communications, simply accessing data from it) First Web Thin Clients – where any node with Microsoft Internet Explorer can login to access and control Runtime data with no extra software required Secure Viewers – where dedicated software install is required, but ensures higher levels of user access security And Studio Mobile Access, which is ideal for mobile devices because of the low data-consumption text-based format


  • 1. Leveraging InduSoft for your Machine Vision Applications Robert Fell Omron Strategic Accounts GroupConfidential © Omron 1
  • 2. Agenda • Introduction to Omron • Machine Vision Basics • Managing a successful Vision Installation • Leveraging InduSoft for Machine Vision ApplicationsConfidential © Omron 2
  • 3. Introduction to OmronConfidential © Omron 3
  • 4. Omron By the NumbersConfidential © Omron 4
  • 5. Omron Product Portfolio • Automation Control Systems – Programmable Controllers – Operator Interfaces (HMI) – Distributed I/O – Software • Motion Controls, Servos, AC Drives – Motion Controls & Servos – AC Drives • Sensors and Vision – Proximity and Photoelectric Sensors – Fiber-optic Sensors – Amplified Photomicrosensors – Measurement, Ultrasonic & Pressure Sensors – Vision Sensors • Industrial Components – Temperature & Process Controls – Code Readers & RFID – Relays, Pushbuttons & Indicators – Limit Switches – Timers & Counters – Power SuppliesConfidential © Omron 5
  • 6. Business Development Group • International project implementation and resource planning • Fully integrated turnkey solutions • Factory AccountabilityConfidential © Omron 6
  • 7. Machine Vision BasicsConfidential © Omron 7
  • 8. Machine Vision Basics • Machine vision (MV) is the technology and methods used to provide imaging-based automatic inspection and analysis for such applications as automatic inspection, process control, and robot guidance.Confidential © Omron 8
  • 9. Key ComponentsConfidential © Omron 9
  • 10. Basic Terms and Understanding Field of View (Blue Area) - Complete area of inspection as viewed upon the vision monitor or HMI. Region(s) of Interest (Yellow Squares) – Specific areas of interest where a particular feature is being inspected for. In this case the blue square represents the field of view while the yellow inspection areas represent the individual regions of interest and the red stars are the features being inspected for.Confidential © Omron 10
  • 11. Basic Terms and Understanding Resolution – Defines the theoretical smallest detectable object per a given field of view and as a function of a certain resolution camera Example: Standard Camera= 640 pixels x 480 pixels Field of View= 4” x 5” Resolution= Dimension of applicable axis in FOV / Pixels per that same axis (per aspect ration of camera) 5” 640 Pixels 5”/640= .0078” per pixel 4”/ 480= .0083” per pixel 4” 480 Pixels Stable detection is typically on the order of 15x the dimension per pixel or 15 x .0078 = .117Confidential © Omron 11
  • 12. System Configuration- Vision Sensor • Streamlined Hardware • Lower Cost • Limited Lensing / Lighting • Limited Tool Set • Single Camera InspectionConfidential © Omron 12
  • 13. Vision Sensor ApplicationsConfidential © Omron 13
  • 14. System Configuration- Box Style • Flexible Hardware Configuration • Mid Range Cost • Multitude of Lensing / Lighting Options • Capable Tool Set • Up to 4 Cameras per controllerConfidential © Omron 14
  • 15. Box Style ApplicationsConfidential © Omron 15
  • 16. System Configuration – Gig E • Flexible Hardware Configuration • Higher Camera Count • Multitude of Lensing / Lighting Options • Most Capable Tool Set and Programming flexibility • 16 Cameras per instance of software • Ease of Indusoft UtilizationConfidential © Omron 16
  • 17. Gig E ApplicationsConfidential © Omron 17
  • 18. Managing a Successful Vision InstallationConfidential © Omron 18
  • 19. Identifying a viable vision application • Identify • Key Features • Machine Discretion & Rationalization • Quantify • Managed Expectations • Start & Stop • Scope Creep • Dollarize • Quantifiable Return on Investment • Known issue • Risk Management/ Litigation • Re-allocation of personnel • Reduced QA TestingConfidential © Omron 19
  • 20. 10 Steps to a Successful Vision Project 1. Identify and document the known issue 2. Quantify specific tolerances and criteria 3. Develop a preliminary scope document detailing expectations 4. Provide a comprehensive set of samples to the vision vendor 5. Request the vision vendor provide a detailed report on the results 6. Pending successful bench testing, schedule an on line trial 7. Upon trial completion re-evaluate scope document and adjust as necessary 8. Develop an acceptance document based on the scope of work detailed 9. Develop budget based on inclusion of comprehensive mechanical, electrical, controls, and installation plan. 10. Agree to a realistic timeline for design, implementation, and run off of the systemConfidential © Omron 20
  • 21. Scope of Work • Project Team • Team Roles • Primary Intent of the Project • Associated partners • Description of current process • Description of desired process • Identification of all key parameters including ◦ Product Types ◦ Defect Types ◦ Line Speed ◦ Environment implications ◦ Machine types • Definition of responsibilities • Requested TimelinesConfidential © Omron 21
  • 22. Acceptance Documentation Example Verbiage“Intention:This document is the formal acceptance documentation for the Omron quality control inspection station being provided toCompany XYZ by Omron Industrial Automation. The Company XYZ purchase order to which this document pertains is 8675309which is being installed on machine ABC in X Location.The criteria by which the system will be judged is below. This information is the exact criteria that Omron committed to in the finalversion of the Performance Guarantee document dated 7/15/2011Structure:This document is structured into 4 major categories, each with their own acceptance sections.Machine SpecificationsInspection SpecificationsCommunicationsSAT CriteriaGeneral Notes:Production of Defects:During the SAT Test described above defects will be produced as follows:Manually creating the (4) described defects.Actual machine created defects .Manufacturing Variation/ Provided Samples:All defects will be created by Omron on site during installation.” Confidential © Omron 22
  • 23. Leveraging InduSoft for Machine Vision ApplicationsConfidential © Omron 23
  • 24. What is OEE Calculation: OEE = Availability x Performance x Quality •Loading: The portion of the TEEP Metric that represents the percentage of total calendar time that is actually scheduled for operation. •Availability: The portion of the OEE Metric represents the percentage of scheduled time that the operation is available to operate. Often referred to as Uptime. •Performance: The portion of the OEE Metric represents the speed at which the Work Center runs as a percentage of its designed speed. •Quality: The portion of the OEE Metric represents the Good Units produced as a percentage of the Total Units Started. Commonly referred to as First Pass Yield FPYConfidential © Omron 24
  • 25. What is OEEConfidential © Omron 25
  • 26. How do we get there? Collection Segregation Visualization Drive down to the ….Confidential © Omron 26
  • 27. Complaints of Machine Vision • Complicated Custom Interface • Complicated recipe management • Very little custom display capability • Misunderstanding drives un-necessary customer interaction and modification • Every application run differentlyConfidential © Omron 27
  • 28. Advantages of InduSoft and Vision -Removing the stress- • Visualization of collected data (non-vendor specific) • Consistency in Interface • Streamlined Recipe Control • Centralization of Information • Simplified User Experience • Custom Adjustment Options By leveraging Indusoft to collect and display data we’re taking a band- aid and turning it into a manufacturing tool.Confidential © Omron 28
  • 29. Actual Screen Shots – Splash ScreenConfidential © Omron 29
  • 30. Actual Screen Shots – Current StatsConfidential © Omron 30
  • 31. Actual Screen Shots- Reject Que Customer XYZConfidential © Omron 31
  • 32. Actual Screen Shots – Production History Customer XYZConfidential © Omron 32
  • 33. Actual Screen Shots - Diagnostics Customer XYZConfidential © Omron 33
  • 34. Actual Screen Shots- Help Documents Customer XYZConfidential © Omron 34
  • 35. Where can you see it…Everywhere!Local or Enterprise/Cloud Web Thin Clients Secure Viewers Automation Data Studio Mobile Access (SMA)Confidential © Omron 35
  • 36. Re-Cap • Properly understanding and deploying inspection equipment throughout your manufacturing process will greatly improve your process and end product. • Utilizing Indusoft as a data collection and visualization tool will take your investment to the next level with its flexibility, ease of use, and ability to turn your inspection data into valuable and actionable production data.Confidential © Omron 36
  • 37. Contact Information Robert Fell Omron Industrial Automation Strategic Accounts Group 630-546-9004 www.omron247.comConfidential © Omron 37