Nuts Bolts & Screws Against a White Background

Doss USA’s visual inspection machines assist several industries with machine learning and AI-based visual inspection systems that learn how to find defective parts as they move through your production line. 

We help the pharmaceutical, fashion, food manufacturing, and home improvement industries to show each of them how to make their processes more efficient and cost-effective for long-term success.

Discover seven ways our visual inspection machines help home improvement product manufacturers

1. Spot Defects More Efficiently

Home improvement products require precise shapes and tolerances for them to work properly, whether you make nuts, bolts, drill bits, washers, or other small parts. As these items move past a conveyor belt, human eyes can’t possibly see minor defects along threads, flutes,  or edges. 

Consider the average batch of 1,000 screws contains 1 percent major defects and 5 percent minor defects. Up to 60 screws can have defects in a batch, even though manufacturers aim for just 30 screws with defects on average.

Visual inspection machines can reduce the number of defects that make it into batches of any size. This improves your product quality, reliability, and trust with your customers.

Related: Pharm Division

2. Perform Statistical Analyses Faster

Machine learning and AI-based visual inspection machines do more than just count the number of defects. These systems have first-class software that analyzes each batch.

For example, a top-of-the-line system can count the number of defects over a batch after rejecting them. But then it can categorize the types of defects based on the measurements the visual inspection system sees. Are your tolerances off by 0.1 millimeters or 1 millimeter? Is the length of a screw too long or too short? The system will flag the most prevalent defects, so your team can determine how to fix things more effectively.

3. Examine Coatings More Readily

Your industrial processes can have two phases when you make home improvement products. The first one creates the main part, while a secondary process coats the main part to protect it.

A visual inspection system can perform pass/fail inspections after the first process for the central part and then after your line coats them to see if the right amount of coating was applied. 

Let’s say you manufacture bolts with very narrow spacing between threads. Part of the batch, after galvanizing, goes through the coating of a castor bean-based coating to protect it from wear. Because the bolts have very narrow spacing, the coating must be precise, or the coating can wear off when a bolt goes into a part. A fully connected visual inspection system can analyze parts and compare the tolerances between both processes. For example, the machine rejects 10 out of every 1,000 bolts on the first pass, but the second pass sees rejects for 50 out of every 1,000. This would indicate you need to tweak your coating process rather than your initial galvanization.

4. Improve Manual QAs

Even when an automatic visual inspection machine moves defects out of the line swiftly, you still have a manual QA process for batches. Improved automatic processes make your QA department more efficient because there are fewer mistakes in those finished batches. Rather, they can spend more time examining the automatically selected defects to troubleshoot your problems more precisely.

5. Lower Risk of Failures

Part failures for some hardware products are not acceptable. Bolts and screws for engine parts must fit precisely, or they could cause breakdowns or even catastrophic failures. 

Lower risks of failures can engender trust with your customers. Fewer problems with vibrations, better assembly of larger parts, improved fit for your customer’s parts, better QAs for your clients’ end products, and lowering the risk of failures makes you more recognized as an industry expert. 

6. Examine All Sides of Surfaces

Human eyes, at best, can see only one side of a part’s surface. As small parts move past quickly, manual visual inspections become impossible.

State-of-the-art visual inspection machines use digital photography that captures all sides of a surface. Multiple camera angles with the right lighting for home improvement products can illuminate and process images almost instantly to signal rejection or acceptance of parts as they move through the line.

7. Optimize Operational Efficiency

Improved defect detection optimizes operational efficiency, allowing your teams to make tweaks more readily while decreasing downtime as you solve problems quickly and more accurately.

As you look over the data analysis that automatic visual inspection systems produce, you narrow down where the problem originates from. Rather than shut a line down to find the difficulty, your experts can locate where the problem comes from, then make necessary adjustments to minimize downtime while improving your batches.

Test Us! We Offer World-Class Visual Inspection Machines

Reach out to Doss USA for more information on our world-class visual inspection systems that can help your teams process home improvement products faster, more accurately, and with better results. 

Contact our U.S. office at (734) 228-5992 today for more information.