System Performance Verification Services

FIBC is proud to announce the Launch of our new System Performance Verification service!

FIBC launched this service in response to the demand for reliable system performance verification testing on high volumes of auditable data sets at low cost.
Vision Systems are an extremely effective method of quality assurance, but only if the system is properly validated that it is providing reliable performance. FIBC’s service is used for analyzing high volumes of camera images to show whether the camera is performing as required. When a Vision System is installed, qualifications on the installation, operation, and performance are often utilized to validate whether the system meets the required specification. Performance Qualifications (PQ) can often be time-consuming and on even on critical system measurements can only be tested against a limited set of data for high volumes. In addition, new qualifications must be performed whenever a change to the product, line, or camera program (or alignment) takes place. This is where FIBC has an innovative, automated, and cost-effective solution.

 

How does it work?

Most cameras are capable of saving images with basic graphic overlays. In most cases, the graphic overlays serve as a reliable output to whether the vision system is performing as expected. A typical case looks like this:

  • Pharmaceutical Company ABC installed a vision system on 25 manufacturing lines for 100% label inspection and requires documented inspection results. As part of the validation they create a handful of good “passing” result samples and a handful of “failing” bad samples and run them several times through the Vision System. In addition, they allow the system to inspect several thousand products and analyze the reject rate. The System passes this qualification and the same test is repeated on all 25 manufacturing lines.
  • Two months later, Company ABC receives a complaint that a critical quality component that the Vision System should have rejected was sent to the field and large penalties, onsite audits, product recalls, and even lawsuits are probable results. Upon closer inspection, it becomes obvious that the vision system has become compromised and is no longer performing as desired. In an effort to minimize such problems in the future, Company ABC turns to FIBC for an automated, continuous validation solution.
  • The Solution FIBC delivers allows for 50 images/day from each line (1,250 images/day) to be automatically uploaded to a secure FTP server where they can be analyzed by FIBC. Although Company ABC could inspect 1250 images/day they estimate that this would take about 3 hours of time for one person to do this task and cost 3x more than FIBC’s solution, so ABC chooses to make use of FIBC as a flexible, on-demand workforce.
  • FIBC analyzes the images from all 25 lines, and in the process, creates a set of images that show where image graphics do not line up as expected, representing cases in process where the vision system is unable to perform reliably. These images are then sent to Company ABC for evaluation. Since these failure modes are happening only 0.01% of the time (1/10,000 products) it was unknown to the Company both the frequency of this failure and that it should have been represented in their initial qualifications of the vision system as a sample defect product to be rejected.


  • Corrections are made to the Vision System algorithm and the automated, continuous validation continues. Three months later, FIBC discovers more image discrepancies that the Vision System is not handling properly and Company ABC realizes that a product or process change had occurred that had unforeseen impacts on the Vision System performance. Again, further improvements are made to the image processing/performance of the system.
  • After 1 year of ongoing validation services (450,000 images analyzed by FIBC), the Vision System performance has had several improvements and Company ABC is now very knowledgeable on the system’s capability and performance. Although Company ABC could call the current Vision System very reliable, they choose to continue using FIBC’s remote support services realizing that upcoming new products could impact the real-time validation and that most of the improvements made thus far underlined a variety of unknown variables not previously considered.


 

The customer has the option of an automated response output. Online Camera Images can be automatically saved and uploaded to FIBC’s secure FTP server. The images are then loaded into a queue and the FIBC’s work volume adjusted to provide timely feedback, periodic reports, or results can be fed back to a customer database.

  • Output on current performance against multiple process & product variables:
    • multiple lines
    • multiple processes
    • multiple product sizes
    • multiple product components
    • multiple product variations

     

What is the Cost?


Processing Volume per Dollar


Typically, cost is pennies on the image! The true cost is a calculation of the time it takes for an image to be analyzed and whether automated services are also being used. Contact FIBC for a free evaluation and a custom solution that fits your needs!

 

How can I know the data is reliable?

Customers can choose whether to have data sets (images) analyzed by one, two, three or more independent IAPs (Image Analysis People) and the results between them provide cross-validation. Additionally, smaller data sets of known results can be randomly inserted into the data stream with requirements that a percentage of those known data sets are agreeable to the IAP results.


Contact FIBC today for a free evaluation!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


 

 

Manager Profile
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Jeremy Turvey

Role: Business Development

With a B. Sc. (Ex. Sc. and Rehab, Hons), Jeremy brings years of experience in both the Insurance and Health Science Industries from Sydney, Australia. Jeremy’s professional experience includes proficiency in:

- Managing his own exercise rehabilitation business. 
- Achieving desirable long term outcomes in complex insurance cases. 
- Managing insurance claims along pathways within stringent legal parameters. 
- Identifying creative solutions for complex personnel issues. 

Jeremy has a special interest in facilitating effective cross-cultural workplaces and is currently seeking this in North West China. Jeremy is a happily married father of three wonderful children. 

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CONTACT US :

Junken masion #1806, West Renmin Road, Korla, Xinjiang, China.

Tel: +86 0996 2909157

Email: info@fairmaninternational.com


Fairman International Business Consulting
新疆费尔曼国际商务咨询有限公司
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FIBC

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