Code reader tracks MP3 player PCBs
A
Cognex UK product story
Edited by the Engineeringtalk editorial team
Feb 5, 2008
Production volume at the plant is 40,000 units a day and so the reading solution deployed had to guarantee a read rate of 99.997%, allowing the production line work nonstop, eliminating down time.
Sony in Malaysia sought a code reading and traceability solution for the PCBs for its MP3 players, protecting itself against costly recalls and product mix ups as well as allowing for "damage control" in the event of a problem.
Previously, badly read codes and the resulting rejection rates were costing the company a lot of money in terms of re-work and rejected units.
Sony in Malaysia is now using the In-Sight 5110 for code reading on PCBs destined for its new MP3 players.
Each PCB passes along a conveyer on nine production lines and is marked with a Datamatrix code containing product information in 10 characters measuring only 1 x 1mm in size.
Production volume at the plant is 40,000 units a day and so the reading solution deployed had to guarantee a read rate of 99.997%, allowing the production line work nonstop, eliminating down time.
Their existing code reading solution had an average rejection rate per week of 10,000 units, which was costing Sony money and was lengthening the time to market.
It is vital that the serial number marked on each PCB heading for product assembly lines be identified and tracked.
If the code reader is not capable of adjusting to product changeovers a serial number can be missed and data is lost.
No two read points are the same.
Lighting, environment, or the way the piece is presented can differ greatly and so a code reading equipment that has the robustness and flexibility to perform reliably under the variants in conditions is essential.
The Cognex In-Sight 5110 ID reader provided a superior read rate in terms of decoding speed and sturdiness.
It offers new perspective distortion support which ensures reliable reading even at an angle to the PCBs.
The job is stored in the reader in such a way as to attempt reading several times using different exposure values, adapting itself to the surface of the PCB and increasing the chances of successful reading.
No reader retraining is required for a product change.
It also offers flexible multiple communication channels and versatile data gathering, which are essential for the factory database.
In-Sight 5110 ID readers are now installed on nine production lines.
Code reading time is now two seconds per read whereas competitors took over 10 seconds to provide a reading.
The code reading success rate has increased from 95% to 99.997%, meaning that the production line no longer has to stop as a result of a badly read code.
There is no longer the need to stop the line for product repositioning or focus adjustment.
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