Innovation in Automated Inspections through Design for Six Sigma

Abstract

The use of automated inspections can result in reduced customer risk due to higher defect detection, but their effectiveness can negatively impact business financials. Previous research shows that inspection methods can yield different results, and these system designs can be optimized. For systems design development, methodologies like Design For Six Sigma have been proven adequate to ensure process design meets its intended purpose. Utilizing a DFSS approach, the inspection systems for an automated packaging process are redesigned. Through the IDDOV methodology, design elements were identified and confirmed, including a control plan to ensure optimized results are maintained. Design concepts were tested and optimized until defined design requirements were met. Expected results from re-design reduce material waste at the inspection points by 90%, and improve vision systems effectiveness, reducing both customer and business risk. Therefore, recommendations within this study lay-out the framework for implementation and qualification of improvements in automated inspection. Key Terms ⎯ automated inspections, design for six sigma, process design development, quality management.