Machine Vision Supported Quality Control Applications in Rotary Switch Production by Using Both Process FMEA and Design FMEA

Emerging in the past few decades, Industry 4.0 has wide effects over production lines with an increasing number of novel applications. These applications implement more than one tools 4.0. include but are not limited to internet things (IoT), big data, cloud computing, artificial intelligence, augmented reality, virtual machine communication (M2M), smart robot applications, etc. The aim these efforts is mainly acquire smarter manufacturing systems. With spreading methodologies, role sensors became important respond new demands. One most sensor types this sense camera which now variants different forms. Applying vision algorithms via cameras grants optimization many critical processes. In perspective, quality both product and process should be handled as a key performance indicator that may continuously enhanced for excellence. Machine adapted check manage designated control points on lines. This study focuses rotary switches widely used household appliances like ovens washing machines. Rotary components appliance since they direct flow electricity within product. A failure functionality component directly causes main Hence, rate calculated defective parts per million (dppm) units. An intense procedure required achieve low dppm rates during production. As real-life application, system integrated into switch line selected point. Classification developed cost-effective platform perform visual checks qualify “Ok” or “Defective”. point ensures high percent criteria while enabling repair minor interventions. identify soon possible defects irreversible once totally produced even some processes completed. case, entire set apart scrap. 
 Another originality our applying Process Failure Mode Effect Analysis (PFMEA) Design (DFMEA) together. There almost no referenced literature. Benchmark comparisons conducted upon completing integration line. result, enhancements quality, cost, speed parameters achieved system. Additional capabilities added system, namely data analyzing online feeding.