5KEYS

FOR IMPROVING PROFITS

WITH MACHINE VISION TECHNOLOGY

KEY 1 ULTRA HIGH-SPEED PROCESSING

Enhanced throughput improves profits

KEY 2 HIGH QUALITY

Higher quality inspections reduce labor and improve profits

KEY 3 VISUALIZATION
Early troubleshooting of root causes improves profits

KEY 4 OPTIMIZATION
Optimal implementation of inspection devices improves profits

KEY 5 QUICK RESPONSE

Quick troubleshooting improves profits
 ULTRA HIGH-SPEED
KEY 1 PROCESSING
Enhanced throughput improves profits

key point HIGH-SPEED PROCESSING

Recently, increasing demand for high productivity in factories and on production lines has made it necessary to also improve product
quality. In order to reach maximum production with minimal investment, it is essential to have a high throughput for each location,
even during tough economic times. Although productivity has improved with technological innovations, quality inspections continue to
often cause delays. In order to increase productivity and improve profits, it is necessary to enhance inspection capabilities by using a
machine vision device that can do reliable high-performance inspections.

Do any of these problems seem familiar?

• Insufficient vision system configurations are used in order to keep up with productivity.
• It is necessary to have several production lines and factories in order to increase productivity.
• The production line is divided into two at the inspection points in order to keep up with productivity.
• Various inspections are allocated to more than one inspection device in order to maintain productivity.

Calculation of improved profits due to enhanced throughput

Enhanced throughput of “10 products/sec. to 100 products/sec.” is realized. A ten-fold increase in throughput increases profits.

( )×
Current
Facility
productivity
inspection
capability
Product
value × Operation
hours = Profit improvement effect

( )×
[ ] [ ] enhanced
products
/min.
products
/min.
$[ ] × [ ] hours × [ ] days = throughput of
$ [ ]/month

Taking full advantage of the multi-core configuration

Key Technology to achieve the fastest processing independent of conditions

The triple-core main DSP has been upgraded to achieve even faster processing. With typical multi-core image processing, parallel
processing was restricted by various conditions. With the CV-X200 Series, each processing unit is capable of distributed parallel
operation, resulting in faster processing independent of conditions. Such ultimate high-speed performance enables high-load
processing using a high-resolution camera as well as operation that requires absolute cycle time.

Typical multi-core image sensor CV-X200 Series

Inspection Core 1 Inspection Core 1

Image capture Position correction … Inspection Core 2 Image capture Position

correction Inspection Core 2

Inspection Core 3 Inspection Core 3

Parallel processing could be used for speeding up inspection, but it could not be used for Parallel operation can be performed in each processing unit. The advantage of the multi-core configuration can
operations such as position correction based on multiple edges. be used most effectively both before and after position correction, ensuring high-speed processing.
The advantage of the multi-core configuration was not used effectively. The CV-X200 Series also distributes display and image saving operations to other cores, offering stable, fast
processing regardless of image saving or other loads.

2
 HIGH QUALITY
KEY 2 Higher quality inspections reduce
labor and improve profits

key point HIGH-QUALITY/RELIABILITY

Amid increases in production line speeds and the diversification of product line-ups, the required quality is becoming higher and higher.
Reliable inspections are necessary in every process in the production lines, and thus, require a lot of labor, time, and other costs to
prevent production of defective products. There are a variety of inspection devices available to reduce labor, however, they are often too
expensive or not reliable. It is impossible to realize continued quality and improved profits without reducing labor.

Do any of these problems seem familiar?

• Visual inspections are performed and it is impossible to do 100% inspections on high-speed production lines.
• A machine vision system was used in the past, but was discontinued due to unstable inspections.
• A machine vision system is being used, however, its inspection capabilities are limited.
• A dedicated inspection device was previously considered, but it wasn’t cost effective.

Calculation of improved profits due to reliable 100% inspections

A “70-fold increase in inspection capabilities/inspection range” is realized due to a “70-fold increase in the number of pixels”.
Effects of “reduced labor + improved reliability”

=
Gross productivity Cost for
Individual inspection capability
× Labor
cost + preventing defective
products
Profit improvement effect

[ ] products/month
[ ] products/month
× $[ ]/
month
+ $[ ] = $[ ]/monthly of
reduced labor
+ Improved
reliability

21 megapixel image processing enables

Key Technology inspection of a wider range and with higher accuracy

A large-sized image of 21 million valid pixels (5104 x 4092) can be

transferred at 16x speed of 110 ms. The new system allows detection
of minute defects or defects in details of a large target, which were 21,000,000 pixels
NEW Details are captured clearly and vividly
impossible with conventional systems. allowing accurate judgement as is.

Defects in an LCD pixel
array can be detected with a
single camera.
5,000,000 pixels
Pixels appear blurry and accurate judgement is
difficult. The field of view needs to be set smaller.
310,000 pixels
It is difficult to identify individual pixels,
not to mention defects.

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 VISUALIZATION
KEY 3 Early troubleshooting of root causes
improves profits

key point VISUALIZATION

Recently, many companies have started to focus on "visualization" and are trying to detect problems as early as possible in order to
improve quality. Inspection processes in production facilities now require inspection methods in which "defective products are accurately
detected" and "solutions can be derived". With machine vision, problems are accurately detected and profit can be improved by
troubleshooting the root cause of problems to find a solution.

Do any of these problems seem familiar?

• Inspections are done with photoelectronic sensors which aren’t able to confirm the type of defects.
• Inspection criteria cannot be set clearly, since there is no processing result data.
• Data is analyzed after it is re-entered into a computer.
• Inspections are unstable because defective products cannot be detected on high-speed lines and inspection
results do not include images.

Calculation of improved profits due to early troubleshooting realized by "visualization"

No preparation time needed for saving “1023 images + 20,000 points of measurement data”.
Preventative measures are taken to eliminate the original cause immediately after detecting the problem.
Production
Time spent
troubleshooting × volume during
troubleshooting
× Unit
price × Frequency = Profit improvement effect

[ ] hours × [ ] products × $[ ] × [ ] times = profit improvement

of $[ ]/month

Key Technology To manage the process, not just the recording. “Statistics”

Up to 20,000 pieces of measurement data can be recorded with the controller alone. It is possible to easily check the value such as
minimum, maximum, average, standard deviation, NG count, and yield rate. In addition to the trend graphs, a list of measured values and
a histogram can be displayed. Also, by using the newly-included function, Process Monitor (process capability index: Cpk), it is possible
to analyze the inspection processes more statistically.

VERTICAL CURSOR
Displays the measured values
and the total count for the
selected cursor position.

IMAGE SAVE MARK

List of measured values Histogram view
■ marked data has its image
data saved. It is possible to
check images by clicking.

Process monitor

4
 OPTIMIZATION
KEY 4 Optimal implementation of inspection
devices improves profits

key point OPTIMIZATION/OPTIMAL EXPANSION

With a wide variety of inspection devices being introduced to the market, many production lines have machine vision equipment from
several different manufacturers and models. There are many situations in which several different models are used together, but the
technicians are not able to learn how to use each device for different applications. Such problems are caused by selecting devices that
are not versatile and that are limited to specific applications. Selecting a highly-versatile device which is capable of handling any type of
application will contribute to improved efficiency, effective asset management, and improved profits.

Do any of these problems seem familiar?

• The production line has many different models with limited functions.
• The machine vision equipment purchased in the past doesn’t perform well in other applications.
• It is possible to only add necessary functions for each application.
• It is desirable to use equipment with a long life expectancy, for example, illumination lamps.

Improved profits due to implementation of highly-versatile devices

The CV Series allows users to avoid purchasing several controllers and illumination devices, reducing the need for inventory and
extra training.

Number of devices Number

purchased due to existing devices' × Unit
price + of × Unit
price + Training
costs
lack of capability existing devices

[ ] models × $[ ] + [ ] models × $[ ] + $[ ] = cost reduction of $[ ]

Multi-camera, simultaneous acquisition system INDUSTRY FIRST

Key Technology

The combination of different types of cameras is possible from 24 types of area cameras and 3 types of line scan cameras. This ensures
the same, familiar operation for different applications and provides the flexibility for easy adaptation to changes that may occur with
inspection criteria. *Some combination may not be possible. Contact us for details.

MULTI-CAMERA SYSTEM EXAMPLE: XG-8700L NEW

DIFFERENT CAMERA COMBINATION EXAMPLE
The entire circumference of the cylinder side is captured into
CA-E800
+ a single image using the line scan camera while it is rotated.
XG-8700L CA-EC80(L·HX) The top surface is captured with an area scan camera and
24 types of the entire workpiece is inspected in one cycle. The
area cameras combination of two different types of cameras results in
reduced inspection times and cost.

3 types of line
scan cameras

5
 QUICK RESPONSE
KEY 5 Quick troubleshooting improves profits

key point QUICK RESPONSE

Reducing problems is always important. However, it is difficult to completely reduce all problems in manufacturing. Although
troubleshooting can resolve many problems, it is also important to have a business partner who can always quickly respond to
emergencies. Profit is significantly affected by how quick the problem is resolved as well as by the establishment of a trouble-free system.

Do any of these problems seem familiar?

• There are limited staff who can resolve problems with the inspection equipment.
• It takes a long time to receive a response concerning problems since communication with the manufacturer is
through an agent.
• Emergency substitutions are not delivered quickly.
• There are no reports output from the inspection equipment.

Improve profits with quick troubleshooting

Quick response to inquiries, substitution service for troubleshooting, and world-wide quick delivery.

Production
volume
× Unit price ×
Difference in time
required for troubleshooting = Profit
improvement effect

[ ] products/time × $[ ] × [ ] hours = $[ ] of avoided loss

Global support by technical staff dedicated to machine vision +

Key Technology a world-wide quick-delivery system

The requirements for an inspection device are that anyone can use it, training support is available, and response time is quick in case
of an emergency. KEYENCE deploys technical sales staff dedicated to machine vision systems around the world and offers inspection
counseling, explanations to run devices after implementation, seminars, and other follow-up services. In addition, substitution devices
in case of an emergency are quickly delivered. KEYENCE is the only company that provides total solutions for machine vision systems,
NEW
illuminations, etc. with dedicated support and inventory throughout the world.

Fast delivery around the world

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 www.keyence.com

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