Quality control time reduction up to 50%
Airbus Poland, located at the Okecie district in Warsaw runs a scope of activities ranging from design, prototyping, manufacturing, maintenance, upgrades, research and development, exchange of technology, to cooperation in the space industry.
Airbus Poland has its own design office, production plant and MRO (maintenance, repair and overhaul) centre providing services to the C295 fleets of Poland, Czech Republic and Kazakhstan. Due to the company’s industrial commitment and information-sharing, some 40% of airframe components in all C295 aircraft sold globally are produced there. Furthermore, about 70% of all electric harnesses for the transport aircraft manufactured by Airbus are manufactured at Okecie.
What was the problem?
As a part of the Startup Spark Acceleration Program, we had a study visit guided by the Head of Quality Control Department, then we quickly learnt about the details of the challenge. All metal parts, in Airbus Poland Quality Control Dept. are measured manually. Operators are checking dimensions of parts 8 hours per day, using tools such as calliper, radius gauge or industrial protractor. Due to limited resources, it’s been impossible to increase production, as each item must have been individually inspected. Manual measurements are time-consuming and often affected by “human errors”. Any incorrect measurement of a part could result in customer complaints or returns.
Once we got familiar with the challenge, we conducted a site visit, where we saw the manufactured parts and the related technical documentation. This initial analysis make us decide to take the challenge. Together with Airbus Poland S.A, we have created an action plan and have prepared next steps to be taken as a part of the acceleration program – Startup Spark.
How did we solve this problem?
The first step was to create a concept of the device and define product specifications in accordance with Airbus requirements. Defining data security requirements was a key issue for the client.
In the next stage, we developed a prototype of the application and device. Then we carried out internal tests of the device and application. At the meeting, we agreed on further actions and adjustments related to ergonomics and application that should be included in the final version of the device. We also carried out another on-site visit to discuss how to implement the device in the Quality Control Department.
The last stage was a creation of the final device based on the prototype, including adjustments from the previous stages. The device uses a high-resolution camera and special lighting. This solution uses a system in which the camera is under a transparent panel, which is illuminated from above. This solution allows to control flat and bent sheet metal parts. The device automatically checks the dimensions of the parts and compares them with the documentation, the user only obligation is to place the element in the right place in the device and check the results.
The device has been tested at an Airbus Poland factory. Preliminary tests showed that the device and the application were working properly.
What business benefits did our client get?
We did not have to wait long for test results, thanks to the client team’s positive attitude towards new technologies and process automation.
Save up to 50% of the time
After initial tests, the device was able to save up to 50% of the time compared to manual control.
Better quality control
Better quality control reduces the number of returns and allows to detect an error at an earlier stage of the process.
By saving control time you can increase productivity, which increases the speed of production itself.
VisionQb Caliper designed by TechOcean has allowed us to optimize production time a lot and avoid human errors. The cooperation with the TechOcean resulted with reliable and complete product.
And that’s how VisionQb Caliper was created
We have noticed that the challenges, we were able to solve with the developed device are also known to other potential clients. After a series of optimizations, VisionQb Caliper was created and it joined the family of our computer vision-based solutions.