pilots
pilot one
Goal: find a more efficient, cost effective, and agile system to carry out the visual and dimensional inspection of thermoplastics parts processed by injection moulding.
Expected outcomes:
- 100% produced parts inspected and scrap significatively reduced.
- a significative improvement in the use of raw materials
- a new quality level, reinforcing the quality standards of the delivered products.
Expected improvements: ↓ 9-12% energy consumption, ↓ 8-12% GHG emissions, ↓ 2-3% waste and rejection rates. ↑ 7-10% the productivity and 3-5% global savings
Solution: ZDZW Visual Inspection Suite
pilot two
Goal: fully optimized thermoforming process for refrigerator inner body production based on innovative AI-enhanced thermal imaging and processing features
Expected outcomes:
- Quality increase of manufacturing process and scrap ratio reduction
- Increase of the controllability of the manufacturing process
- Successfully feedback to machine to optimize its parameters automatically
Expected improvements: ↓ 8% Scrap ratio, ↓ 10% energy consumption; ↑ 10% efficiency; ↑ 25% data quality and 2,3M€/year global savings
Solution: ZDZW Thermal Inspection Suite
pilot three
Goal: reduce defects of welding and painting during the wind turbine tower manufacturing process
Expected outcomes:
- reduction of repairing costs for welding processes
- improvement of automatic defect detection and feedback for real-time monitoring and welding control
- minimisation of direct involvement of operators during welding under complex conditions
- improvement of inspection-repair time in the painting process
Expected improvements: ↓ 15% reduction of repairing costs for welding, ↑ 25% inspection-repair time for painting; ↑ detection and repair of 98% of all defects prior delivery
Solution: ZDZW Integrity and Thermal Inspection Suites
pilot four
Goal: monitor the induction hardening process in real-time for bolt manufacturing used in the wind industry
Expected outcomes:
- reduction of required destructive tests
- increase of productivity and scrap reduction
- improvement of component internal mechanical properties (better, more durable, and lighter).
Expected improvements: ↓25% energy consumption, ↓ 50% waste, ↓ 100.000€ production cost/year; ↑ 33% production
Solution: ZDZW Integrity Inspection Suite
pilot five
Goal: cost-effective in-line inspection of ceramic antenna modules used for in-vivo medical applications
Expected outcomes:
- Defect identification to stop the process without wasting hours or days of machine time
- Process optimisation via real-time adjustment of the printing parameters such as speed, temperature, amount of material and pressure chamber temperature
- A quality statement record for each and every component can be provided based on the recorded data.
Expected improvements: ↓50% rejected antenna modules, ↓ 2,5t of ceramic/year, ↓12,5% energy consumption; ↑ 9M€/year savings
Solution: ZDZW Integrity Inspection Suite
pilot six
Goal: real-time control of the coffee capsule forming process, monitoring the quality of individual and assembled components during the various phases of capsule assembly.
Expected outcomes:
- Reduce of the actual use of current destructive sample testing
- Limiting the rejection only to the defective capsules
- Reduce of energy and material waste including the expensive one of the raw material, i.e. coffee.
Expected improvements: ↓ 10t/year or generated waste, ↓ 1% defects, ↓1% energy consumption
Solution: ZDZW Visual Inspection Suite
