Electronics / Industrial Automation
100% traceability achieved through stage-wise barcode scanning across 15+ test points.
24×7 unmanned operations implemented eliminating human supervision and operator fatigue.
Zero manual intervention in rejection handling—robotic segregation triggered via PLC logic.
The Challenge
The Solution
The Results
- The client needed a completely unmanned quality testing line for products moving through 15+ testing stations across multiple conveyor lines.
- Manual scanning or human supervision was not feasible due to round-the-clock operations, high speed, and the need for precise routing based on test outcomes.
- They required a solution capable of:
- Identifying products using laser-etched barcodes.
- Validating testing sequence logic (e.g., skip rejected units).
- Triggering robotic actions for rejected products—all in real time and with no human intervention.
DDAPL delivered a robust automated tracking and control system using:
- Fixed Mount Barcode Scanners
- Positioned at every testing station to instantly scan laser-marked barcodes as products passed.
- Connected to a central logic system without human intervention.
- Integration with Mitsubishi PLC over Profinet
- Scanners communicated with the PLC network using the Profinet protocol for real-time data exchange.
- PLC verified if previous stage testing was completed before allowing the current test to proceed.
- Sensor-Based Triggering System
- Optical sensors at each station detected incoming products and activated barcode scanning automatically.
- Conditional Routing via PLC Logic
- Based on scan validation:
- If product passed the prior test, the current test ran and result (Pass/Fail) was logged.
- Based on scan validation:
If the product failed, PLC signaled a robotic arm to pick and place it in a rejection bin—without any manual judgment or delay.
- Fully automated, hands-free operation across 10 production lines and 15+ testing stages.
- 24×7 system availability with zero operator fatigue, enabling consistent quality control.
- 100% traceability of each unit through barcode scanning at every stage.
- Instant rejection and segregation of failed units using robotic automation.
- Seamless Profinet communication between barcode scanners and Mitsubishi PLC ensured real-time decision-making and test validation.
- Reduced downtime and human error, freeing manpower for higher-value tasks and increasing test line reliability.
Additional Benefits and Future Enhancements
- Scalability Across Lines: Solution architecture supports expansion to additional conveyor lines and test stations without major overhaul.
- Advanced Analytics: Future dashboards can analyze test failures by station, time, or SKU to identify performance bottlenecks.
- Predictive Maintenance: Integration with equipment health monitoring systems can reduce unexpected downtime.
