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Optiplan

Automated Quality Control
Thanks to Artificial Intelligence

OPTIPLAN GmbH has been producing glass fibre reinforced plastics in the form of plates and rolls for over 60 years. The traditional company based in Oelsnitz (Vogtland) offers tailor-made solutions for commercial vehicles, construction and industry. As one of the leading and most innovative manufacturers in this field, OPTIPLAN relies on the latest technologies: Together with T-Systems MMS, the Saxon company carried out a proof of concept for an AI-supported quality control, which also included the automatic detection of individual defect classes.


Customer Benefits


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Improved efficiency and accuracy in quality control due to AI support

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The improved product quality meets the growing quality demands of the customers

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Claiming the market and competitive position of OPTIPLAN as a pioneer in innovation

Felix Bönsch, Technical Manager OPTIPLAN

„We focus on innovation not only in our products, but also in production.
With an optical quality control system supported by artificial intelligence, we can detect defects automatically.
Together with T-Systems MMS, we have proven this with a concept and model test. Further proof of our pioneering role!"


Reference Summary


Task

Task

The time-consuming manual quality inspection is to be made more efficient

 

Solution

Solution

Consulting, conception and proof of concept of an individually developed AI solution for optical quality inspection

 

Benefits

Result

Automated detection of errors and defects during production

 

  • Requirements

    Detect Quality Defects Automatically

    OPTIPLAN manufactures fiber-reinforced plastic in webs and as sheets in continuous and discontinuous production lines. Various processing steps are carried out during production, at the end of which there is a manual quality inspection by a specially trained employee. His task is to manually mark defective areas such as bubbles, thickenings and inclusions.
    This time-consuming and staff-intensive testing process is to be replaced by an AI-supported process. Based on a feasibility study, T-Systems MMS was commissioned to evaluate whether an AI-based optical quality control system can reliably and permanently identify defects on the plastic webs during production and thus automate quality assurance.

  • Solution

    Optical Quality Control With AI Model

    In AI-supported optical quality control, the condition of the manufactured products along the production line is initially recorded by video camera. The acquired optical sensor data is processed using artificial intelligence by a specially developed computer vision approach for error detection. Occurring anomalies are extracted, displayed and saved. At the same time, an employee is informed in order to carry out the necessary measures to reduce errors. An edge device is used directly on the camera to calculate the data. The individual development of the AI components is carried out in advance using raw video footage on a platform from T-Systems MMS, which provided consulting, design and implementation of the proof of concept.

  • Benefit

    Innovative, efficient monitoring of product quality

    Due to digital sensory monitoring of the manufacturing process, errors and defects are now detected during the production of fiber-reinforced plastics. As a result, the hitherto time-consuming process of quality control is considerably more efficient. In addition, valuable data for the adjustment of the production plant and material properties are obtained. Relieving the workload of the employees leads to a more flexible deployment along the production line and thus to an overall more efficient production process.

    This not only contributes to customer satisfaction, but also strengthens OPTIPLAN’s leading role in product development as well as in the production of fiber-reinforced plastics.

About OPTIPLAN GmbH

OPTIPLAN operates two continuous and six discontinuous production plants for the production of fiber-reinforced plastics (FRP) at its headquarters in Oelsnitz. This enables both production processes – unique in the world – in one place and from a single source. The GRP sheets and membranes are used for composite elements and sandwich panels in industry, construction, commercial vehicles, motorhomes and caravans. OPTIPLAN is part of the Senata Group.


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