Undetected glass defects from scratches and inclusions to structural issues may result in high completed unit rejects, decreased efficiency and increased production costs. If the defects go completely unnoticed until the glass is received by a disappointed customer, future profits can also be at risk. Since many important defects can be difficult to observe, even with a trained eye, we suggest investing in scanning equipment that would allow for an automated detection and notification process.
Scanning equipment is relatively new in the US flat glass industry, but as more businesses move towards the vision of Industry 4.0, it will become a critical component on the production floor. There are three major considerations when searching for the right piece of scanning equipment:
1. Placement/role in the production line
2. Critical defects for detection
Role in Production
Where are the bottlenecks and issues in the current production? Are there certain areas where it is critical to find defects before continuing the production process? These are just a few of the important questions needed to make this decision. Different scanners and their various models are designed for certain locations and production flows.
For example, the GlassInspector OPT was created to optimize the glass cutting process. When installed before the cutting table (after the loader), it will help to optimize cutting and reduce the rejection rates. The scanner finds basic and advanced defects and will send the information to the cutting reoptimization software so that a new cutting plan can be created to place the defects in the scrap pieces of glass allowing for quicker and easier rejection by the operator.
Depending on your production levels and needs, there are various defects that may need to be detected. From the more standard (marks and superficial scratches) to more advanced defects (white haze and structural issues), all scanners have different defects that they can identify, depending on camera type and software. Your decision regarding any defect may also depend on the quality levels expected by your customers or for various projects.
The original GlassInspector (typically used in an IG line) can detect bubbles, inclusions, scratches, abrasions, fingerprints, etc. which are then displayed and classified based on provided parameters. There is also a profiler option which is used to ensure the correct dimensions of the glass and the shape/diameter of holes in the glass. Additionally, defects such as halos and white haze can be detected if that is a production need.
Many scanners have various customization options available. If working with shower doors, a customized option for dimension and printing detection could be valuable. Additionally, some scanners can be customized based on automation needs. For those moving rapidly towards Industry 4.0 a highly automated scanner may be necessary, while some businesses only require a semi-automatic process.
While all Deltamax scanners are customizable, the GlassInspector EVO is the most versatile and customizable model. In addition to adding multiple types of detection, various types of cameras are available based on your specific needs. EVO also has a unique production analyzer software option that can track the frequency of different types of defects and rejections so that you can find and fix any root problems.
Overall, investing in a flat glass defect scanner can be a complex choice with an overwhelming amount of options. If you choose to work with a sales rep from Matodi, we can help you navigate these choices based on your current production needs and the goals.