Precision Fluid Monitoring

For aerospace manufacturing

Our client, a leading manufacturer of precision aerospace components, tackles the challenge of flawless production and precise fluid application to meet stringent quality standards.

CLIENT

Growing manufacturing facility - Confidential

Industry

Aerospace Manufacturing

ENGAGEMENT

Since mid 2019 till present. 

TECHNOLOGIES

React Native, Redux for State Management, Node.js, Express.js, 

PLATFORMS

Machine leaning algorithm

Counting Every Drop: Implementing Video Processing for Precise Fluid Management in Critical Manufacturing"

Company Profile

Company: Confidential
Industry: Aerospace Component Manufacturing
Location: Portland, Oregon, USA
Size: 500 Employees
Annual Revenue: ~$150 Million

BACKGROUND

Client specializes in manufacturing critical aerospace components, where even the minutest flaw can have significant ramifications. Known for its commitment to unparalleled precision and quality, Client faces the continuous challenge of ensuring each component meets rigorous standards, a challenge compounded by the need for meticulous fluid application in many manufacturing processes.

APPROACH

In late 2019, Client’s Director of Quality Assurance reached out to us after coming across our case study on advanced video processing for fluid management at an industry conference. He was particularly interested in how our solutions could enhance their fluid application processes, crucial for cooling and lubrication during the manufacturing of aerospace components. Despite rigorous quality control measures, Client struggled with ensuring the precision of fluid applications, often leading to costly rework and waste.

NEEDS AND CHALLENGES

Client presented us with a detailed overview of their needs and the challenges they were facing:

  • Precision in Fluid Application: Certain aerospace components required exact amounts of cooling fluids during manufacturing to maintain integrity. Even slight deviations could lead to defects.
  • Real-Time Monitoring and Adjustment: Client sought a way to monitor and adjust fluid application in real-time to prevent waste and ensure each component met strict aerospace industry standards.
  • Integration with Existing Systems: Any proposed solution needed to seamlessly integrate with their current manufacturing and monitoring systems without significant downtime.
  • Data Scarcity: Client had limited data on the correlation between fluid application inaccuracies and component defects, complicating efforts to precisely target the problem areas.

OUR SOLUTION

After a series of consultations, we proposed a customized video processing solution tailored to Client’s specific needs. Our approach included:

  • High-Resolution Video Monitoring: Implementing high-resolution cameras capable of capturing the fluid application process in detail, even in the challenging lighting conditions of a manufacturing environment.
  • Advanced Video Processing Algorithm: Developing a bespoke algorithm to analyze video data in real-time, accurately counting and assessing the volume of fluid applied to each component.
  • Integration Protocol: Creating a detailed plan to integrate our solution with Client’s existing manufacturing systems, ensuring minimal disruption to their operations.
  • Data Analysis and Feedback Loop: Establishing a feedback loop that used the collected data to not only monitor and adjust fluid application in real-time but also to inform Client of long-term trends and potential areas for process improvement.

IMPLEMENTATION AND RESULTS

Our team worked closely with Client to implement the solution, conducting on-site installations and training for their staff. Within the first three months of implementation, Client reported significant improvements:

  • Increased Precision: The accuracy of fluid application improved by over 95%, directly contributing to a higher yield of defect-free components.
  • Real-Time Adjustments: The system’s real-time feedback allowed for immediate adjustments, significantly reducing waste and rework.
  • Seamless Integration: Our solution integrated smoothly with Client’s systems, with Director of Quality Assurance  noting, “The transition was seamless, and the impact was immediate.”
  • Informed Decision-Making: The data collected provided Client with insights into their manufacturing processes they hadn’t had before, enabling more informed decision-making and process optimization.

CONCLUSION

Client’s story is a testament to the transformative power of innovative technology in addressing specific manufacturing challenges. Our solution not only enhanced the precision and efficiency of Client’s manufacturing processes but also empowered them with actionable data, setting a new standard for quality in aerospace component manufacturing.

FAQs

What is Precision Fluid Monitoring?

Precision Fluid Monitoring refers to the use of advanced video processing and analysis technology to ensure accurate application of fluids in manufacturing processes, crucial for maintaining quality and efficiency in the production of aerospace components.

How does Precision Fluid Monitoring enhance aerospace component manufacturing?

It improves manufacturing precision by enabling real-time adjustments to fluid application, significantly reducing waste, and ensuring each component meets stringent quality standards, essential in aerospace manufacturing.

What technologies are involved in Precision Fluid Monitoring?

The solution employs high-resolution industrial cameras, custom video processing algorithms, and machine learning for real-time quality assurance and automated fluid management, integrated seamlessly with existing manufacturing systems.

Can Precision Fluid Monitoring be integrated with any manufacturing process?

Yes, the technology is designed for flexibility and can be integrated into various manufacturing processes, requiring minimal adjustments to existing workflows and systems.

How was data augmented in this Precision Fluid Monitoring case study?

Data augmentation involved enhancing our algorithms with synthetic data and real-world testing scenarios, improving the system's accuracy in detecting and analyzing fluid application under diverse manufacturing conditions.

What were the key outcomes of implementing Precision Fluid Monitoring?

The implementation led to over 95% improvement in fluid application precision, reduced product defects, minimized waste, and fostered a more efficient, streamlined manufacturing process.

How does Precision Fluid Monitoring contribute to sustainability in manufacturing?

By significantly reducing waste and rework, Precision Fluid Monitoring helps manufacturers minimize their environmental footprint, making aerospace component production more sustainable.

Are there any specific industries, aside from aerospace, where Precision Fluid Monitoring can be applied?

While tailored for aerospace, this technology is applicable across various industries requiring precise fluid application, such as automotive, pharmaceuticals, and electronics manufacturing.

How can I learn more about implementing Precision Fluid Monitoring in my manufacturing process?

For more information on integrating Precision Fluid Monitoring into your process, contact us directly. Our experts are ready to tailor the solution to your specific manufacturing challenges.

TECHNOLOGY STACK

To implement the solution for our client, we utilized a comprehensive technology stack designed to address their specific challenges in fluid application for aerospace component manufacturing. This stack included both hardware and software components, tailored to integrate seamlessly with Client's existing systems. Here's an overview of the key technologies used:

Camera
HARDWARE

High-Resolution Cameras

Industrial-grade cameras capable of capturing detailed video footage at high frame rates, ensuring every moment of the fluid application process is recorded with precision.

Sensor
HARDWARE

Sensors and Actuators

A combination of sensors to detect the presence of components and actuators to adjust fluid application mechanisms in real-time based on the video analysis.

opencv
SOFTWARE

OpenCV
(Computer Vision Library)

Utilized for its powerful image processing and video analysis capabilities, allowing us to develop custom algorithms for detecting and analyzing fluid drops in real-time.

python
SOFTWARE

Python

Served as the primary programming language due to its extensive library support, including for OpenCV, and its suitability for rapid development and integration with various systems.

pytorch
SOFTWARE

PyTorch
Machine Learning Frameworks

Employed for developing and deploying machine learning models, enhancing the algorithm's ability to adapt and improve from accumulated data over time.

node-js
SOFTWARE

Node.js

Used for developing the backend of the monitoring system, enabling real-time data processing and communication between the video processing system and Client's manufacturing systems.

react native
SOFTWARE

React

Chosen for the frontend to create an intuitive user interface for operators and quality assurance personnel, allowing for real-time monitoring and adjustments.

kubernetes
SOFTWARE

Docker and Kubernetes

Utilized for containerization and orchestration, ensuring the solution's components could be deployed and scaled efficiently across Cascade's infrastructure.

MQTT
Integration and Communication Technologies

Message Queuing Telemetry Transport

A lightweight messaging protocol used to facilitate communication between the video processing system and Client's manufacturing equipment, ensuring fast and reliable message delivery even in the bandwidth-constrained environments typical of industrial settings.

RESTfull API
Integration and Communication Technologies

RESTful APIs

Implemented to enable seamless integration with Cascade's existing ERP (Enterprise Resource Planning) and MES (Manufacturing Execution Systems), allowing for automated data exchange and process adjustments based on the analysis.

database
Data Storage and Analysis

SQL and NoSQL Databases

A combination of database technologies was used to store structured data (e.g., component specifications, fluid application parameters) and unstructured data (e.g., video analytics results), facilitating efficient data retrieval and analysis.

powerbi
Data Storage and Analysis

Power BI

 Integrated to provide Client's management and operational teams with actionable insights through dashboards and reports, highlighting trends, performance metrics, and areas for process optimization.