Case Study: Enhancing Precision and Efficiency for a Singaporean Hardware Manufacturer
Introduction:
This case study highlights a successful automation project for a discerning client based in Singapore, specializing in the manufacturing of high-precision small hardware components. The challenge was to automate the packaging process for large quantities of tiny, intricate parts, ensuring absolute count accuracy and superior product presentation.
Client Profile:
Our client is a leading supplier of precision-engineered small hardware (e.g., miniature screws, bolts, washers, and electronic connectors) to global industries where quality and reliability are non-negotiable.
The Challenge:
Manually counting and packaging batches of 1,000 to 2,000 small, often similar-looking components was a time-consuming process prone to human error. Inaccuracies in count could lead to customer dissatisfaction, production delays for their clients, and significant financial loss. The client required a robust, high-speed, and error-proof solution.
The Solution: A Fully Integrated Vision Counting & Packaging System
1. Automatically feeding machine
To better convey products to counting machine and consistantly counting products to keep speed, feeding machine is a good chioce. Feeding machine is able to be customized device to connect with previous process machines then automatically feeds products to visual counting machine. Herewith red laser to check and keep products quantity in hopper(visual counting machine).
2.High-Speed Visual Counting
The core of the solution is an advanced vision-based counting system. Components are fed onto a vibrating plate and dispersed into a single layer on a high-resolution backlit conveyor. A powerful industrial camera captures detailed images of the parts. Sophisticated software algorithms then accurately count each item, even when they are densely packed or overlapping, ensuring a precise count of 1000-2000 pieces every cycle.
3.Automated Bagging with Integrated Vacuum Sealing
Once the correct quantity is confirmed, the system automatically dispenses the counted components into pre-made bags. To provide added value and enhance product protection for international shipping, the packaging station is equipped with an integrated vacuum sealing function. This process removes air from the bags, significantly reducing their volume, preventing internal movement, and protecting the components from oxidation and moisture during transit.
4.Final Weight Verification Check:
Understanding that absolute accuracy is critical, the system incorporates a final quality assurance checkpoint. The vacuum-sealed bags gently drop onto a high-precision weight checkweigher. This machine instantly verifies the total weight of the bag against a pre-set acceptable range. Bags that fall within the correct weight tolerance are confirmed to contain the exact number of components and are automatically passed to the next station for cartoning or palletizing.
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