常盤産業 Product Lineup

We would like to introduce a case where we manufactured and implemented a prototype machine for evaluation aimed at automation for Company N, a manufacturer of automotive parts. In the all-direction inspection of long workpieces in square pipe shapes, inspections were traditionally conducted by human eyes. However, in order to improve operational efficiency, automation was considered, and there was a request to achieve all-direction inspection in one go without changing setups. After conducting detailed hearings, we proposed a device that performs automatic inspections from four directions—up, down, left, right, and diagonally—totaling eight directions, all without changing setups within a limited space. As a prototype machine, we realized the automation of the inspection process, and a prospect for operational efficiency was established. [Case Overview] ■ Background: All-direction inspection of long workpieces without setup changes ■ Proposal: Zero-start automation ■ Effect: Outlook for operational efficiency *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the automation line for multi-variety bottle filling that was implemented for Company J, a medical materials manufacturer. In addition to accommodating a very diverse range of work, there were several challenging requirements, including operation in a darkroom environment to prevent any impact on the contents, precise alignment of covers and caps, and achieving a cycle time of 30 units per minute. We proposed an automation line covered with light-shielding covers that consistently handles everything from supply to appearance inspection, accommodating multiple varieties. Continuous production at the required cycle time was achieved, realizing both high production efficiency and stringent quality assurance. [Case Overview] ■ Background: Multiple challenging requirements including multi-variety accommodation ■ Proposal: Various innovations for multi-variety accommodation ■ Effect: Achieving high production efficiency and stringent quality assurance *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the automation equipment implemented for the bagging process of nozzle parts at a medical materials manufacturer. In the process of packing a specified number of nozzle parts into a ziplock bag and sealing it, this was traditionally done manually. However, maintaining strict quality conditions without causing scratches or deformation to the workpieces while improving production efficiency was a challenge. We proposed a system that divides the tasks of picking parts and bagging, intentionally leaving the supply of parts to the hopper and the setting of empty bags as manual operations. Through stable automation that meets quality standards, we achieved a significant improvement in production efficiency. [Case Overview] ■ Background: Balancing strict quality conditions and efficiency ■ Proposal: Intentionally leaving manual operations ■ Effect: Significant improvement in production efficiency *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where Company C, a metal processing manufacturer, implemented automation equipment for the measurement of the total length of cap parts and the sorting process. In the measurement and sorting of cap parts, which are lathe-processed products, it was necessary to avoid interference with measurement accuracy caused by the entanglement of cutting chips and to ensure stable measurement accuracy, as well as to reduce the complicated adjustment work on-site. To avoid interference from cutting chips, we proposed a method for high-precision total length measurement by placing contact-type displacement sensors above and below. The entire process from material feeding to automatic sorting has been fully automated, achieving a reduction in the burden on operators and optimizing production efficiency. [Case Overview] ■ Background: The challenge was to ensure stable measurement accuracy and reduce adjustment work on-site. ■ Proposal: Various suggestions to reduce adjustment work. ■ Effect: Achieved a reduction in the burden on operators. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of Company B, a medical materials manufacturer, which implemented an automated line as the second model, improving upon the first model produced by another company. The first model from another manufacturer faced issues such as chocolate stops, poor contact, adhesive vapor retention, and difficulty in cleaning. With the increase in production volume, there was a need for the second model to address these challenges. We confirmed the problematic areas on-site and proposed various measures, such as the adoption of waterproof connectors and a review of the vibration-proof mechanism. The entire process was fully automated, achieving long hours of stable operation and a highly automated line that is safe and easy to manage. 【Case Overview】 ■ Background: Development of the second model with improvements to the first model from another company ■ Proposal Details: On-site inspection of the actual equipment and proposal of various measures ■ Effect: Achieved a highly reliable, safe, and easy-to-manage automated line *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the implementation of an automation system for jig placement in the circuit board cutting process at electronic components manufacturer Company A. In the circuit board cutting process, it is necessary to create dedicated jigs for each board, which incurs costs and lead times for small lot production of various types, making it difficult to respond quickly to design changes. We proposed a magnetic pin automatic placement system that eliminates the need for dedicated jigs entirely. By automating all processes of pin installation, confirmation, and return, we achieved significant cost reductions and dramatically shortened production lead times. [Case Overview] ■ Background: Cost reduction in processes requiring small quantities of various types ■ Proposal: No need for dedicated jigs! New magnetic pin automatic placement system ■ Effect: Achieved significant cost reductions and shortened lead times *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the introduction of high-speed automation equipment for the visual inspection process of precision electronic components at Company F, a manufacturer of metal and resin parts. In the manufacturing process of precision electronic components, there was a demand for reducing cycle time to improve productivity, necessitating the establishment of a system for inspecting all units within an extremely short tact time for fine and diverse defects. We proposed a mechanism centered around an index table equipped with eight arms, allowing each inspection process to proceed simultaneously. This enabled comprehensive visual inspection from multiple directions with high precision imaging, significantly contributing to a leap in production efficiency. 【Case Overview】 ■ Background: High-precision image inspection of six surfaces with a cycle time of 1 second ■ Proposal: Imaging process optimized for efficiency ■ Effect: Dramatic improvement in production efficiency through comprehensive visual inspection in 1 second *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the automation line for appearance inspection and packaging of resin molded products implemented at G Company, a manufacturer of metal and resin parts. Due to the aging of existing inspection machines, there were challenges in detecting various defects in complex-shaped workpieces, inspecting the top and sides within a short takt time, and efficiently supplying and retrieving large quantities of heavy workpieces. We proposed a system that combines a vertical multi-joint robot with advanced image inspection equipment to reduce travel time losses. We achieved consistent automation from inspection to packaging, promoting labor savings and simultaneously reducing the burden on the production site. [Case Overview] ■ Background: Inspection process requiring speed, volume, and precision ■ Proposal: Thorough reduction of time losses ■ Effects: Improvement in quality and efficiency, as well as reduction of the burden on the site *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of an automatic inspection device that performs dent inspection by combining a 3D sensor and AI, designed as a concept for our exhibition. In the conventional full dent inspection of metal workpieces, human eyes were used, but standard cameras faced challenges as the metal reflected light, causing halation and making it difficult to consistently capture dents. By combining a 3D sensor with AI image inspection software and integrating a robot for comprehensive inspection, we created a demo device. This has led to the realization of an automated device for full dent inspection with zero blind spots, unaffected by environmental conditions. [Case Overview] ■ Background: Full dent inspection of glossy workpieces ■ Proposal: Automatic inspection device effectively utilizing a 3D sensor ■ Effect: Achieved a full dent inspection device with zero blind spots *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the automation equipment introduced for the lead frame dent image inspection process at metal press manufacturer K. In the production line of lead frames discharged from the existing press machine, it was necessary to add an inspection process to check for dents without dropping the production takt time and while preventing the influence of stray light, all within a limited allowable space. We proposed the addition of a compact image inspection unit that fits within the existing equipment, and implemented measures to prevent stray light by placing a high-resolution camera and lighting. This enabled automatic dent inspection inline without any reduction in production speed. 【Case Overview】 ■ Background: Retrofitted inspection process for existing line ■ Proposal: Compact inspection unit that does not interfere with takt time ■ Effect: Automation of inspection without any reduction in production speed *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the automation equipment for the visual inspection of white disc-shaped workpieces implemented at H Company, a manufacturer of resin molded parts. With the start of mass production of white reflectors, there was a need for high-speed inspection of up to 1 million workpieces per month, covering 360 degrees around the top, bottom, and outer side surfaces, as well as the detection of fine foreign objects and black spots as small as 0.3 mm. We proposed a system incorporating an inversion mechanism and a rotating mechanism for side appearance inspection, achieving reliable automated inspection that is not affected by the environment. The efficiency of the packaging process has also improved. [Case Overview] ■ Background: 360-degree inspection with a minimum NG of 0.3 mm ■ Proposal Details: Proposal incorporating an inversion mechanism and a rotating mechanism for side appearance inspection ■ Effect: Realization of reliable automated inspection *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study of the implementation of an automatic inspection device at automotive parts manufacturer M Company. There was a need to automate the visual inspection of ring-shaped workpieces, but the inspection involved determining shallow and thin cracks, which were difficult to see with the human eye. The process relied on the auditory judgment of a single veteran staff member. By conducting thorough preliminary verification and innovating the shooting methods, such as adjusting the angle of the lighting, we proposed an automatic inspection device that could determine the presence of cracks, including both upstream and downstream processes. This has eliminated reliance on individual expertise and has also led to improved production efficiency. [Case Overview] ■ Background: Only one veteran could perform the inspection ■ Proposal: Thorough preliminary verification before the proposal, tailored to the customer's needs ■ Effect: Automatic inspection device including upstream and downstream processes *For more details, please download the PDF or feel free to contact us.