Why Industrial Imaging Cameras Are a Game-Changer for Your Operations

Get ready to level up your quality control game…

Every manufacturer wants to know: how can I improve inspection accuracy? Speed up my quality control? Eliminate defective products?

Because if you can catch defects early in the manufacturing process you can:

• Reduce production costs
• Improve overall product quality
• Create happier customers

The challenge is:

Manual inspection is no longer fast enough. Eyeballs only can’t keep up with today’s production volumes. Your quality control team works hard but human vision is imperfect.

Humans get tired. Humans make mistakes.

Industrial imaging cameras are the game-changing solution that can help manufacturers and industrial companies solve these problems. They are the tech your quality control processes need to enter the next level.

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What Are Industrial Imaging Cameras?

Industrial imaging cameras are specialised cameras designed to perform in harsh industrial conditions.

They are built to withstand high and low temperatures, dust, vibration and continuous operation. With industrial imaging cameras, you can capture high-resolution images at rapid speeds to perform inspection, measurement and quality control.

Industrial imaging cameras provide a set of eyes that never blink or lose focus.

Working in conjunction with machine vision systems, industrial cameras can automatically detect surface defects, verify assembly, count components and more. They ensure every single product leaving your facility is up to your standards. And they do it consistently and without human error.

Industrial imaging cameras are available from a variety of trusted suppliers, including the VA Imaging industrial camera collection. The camera collection is available in a range of models designed for use in a variety of manufacturing and inspection applications.

Pretty neat right?

Why Your Operations Should Be Using Industrial Imaging Cameras

Here’s a fun fact that you may not know…

The industrial camera market is expected to experience significant growth in the coming years.

In fact, Allied Market Research reported that the industrial camera market was valued at USD 1.9 billion in 2020. It is expected to reach USD 4.7 billion by 2032.

You can probably guess the reason for this strong growth.

Industrial imaging cameras meet a real and growing need for smart manufacturers looking to gain a competitive edge.

Let’s look at the key reasons why your manufacturing, production or industrial operation needs industrial imaging cameras right now.

Superhuman Defect Detection

Human visual inspection is limited.

A study by the National Institute of Standards and Technology found that visual inspection error rates increased by 20% after just 30 minutes of continuous inspection. That is a serious problem. Fatigued inspectors make more mistakes and allow more defects to escape detection.

Industrial imaging cameras don’t get fatigued. They can automatically detect surface defects as small as 0.1mm with accuracy rates of 99% or greater. They can operate 24/7 without breaks or fatigue and without the inconsistency that comes from human decision-making.

Defective products that make it to your customer will rapidly go down.

Faster Production Speeds

Speed is money in the manufacturing industry.

Industrial imaging cameras can operate at extremely high frame rates to keep up with the fastest production lines. These systems can analyse images in less than 20 milliseconds. That is less time than it takes you to blink your eyes.

Thanks to this high-speed performance, you can perform real-time inspection without slowing down the production line at all. Each product is inspected in-line as it moves through the manufacturing process. Defects are caught the moment they occur. No bottlenecks. No downtime.

Serious Cost Savings

Talk is cheap. Let’s look at the numbers.

The average industrial imaging system will provide a return on investment in 6 to 18 months, some faster. This is the result of lower labour costs, better quality and reduced scrap rates. Let’s drill down into the potential savings:

• Fewer dollars spent reworking defective products
• Reduced customer complaints and returns
• Lower labour costs for inspection personnel
• Less waste from catching defects before products move too far through the process

The up-front capital expenditure is often more than paid for by the resulting cost savings.

Consistency You Can Count On

Your team of human inspectors are inconsistent.

We all have good days and bad days. We may catch a defect one day and then miss the same defect on another day. Two different inspectors may view the same defect and make a different call.

Industrial imaging cameras provide absolute consistency. The same criteria are applied to every single part. Every product is inspected in the same way, with the same degree of accuracy at 3AM as 3PM. That is consistency that only automated machine vision systems can provide.

The Industries Benefiting Most

Industrial imaging cameras are used by a variety of industries.

The top segments using industrial imaging cameras include:

• Automotive: Industrial imaging cameras can be used to perform part inspection and assembly verification.
• Electronics: Industrial imaging cameras can be used to perform PCB inspection and component placement.
• Pharmaceuticals: Industrial imaging cameras can be used to perform packaging compliance and contamination detection.
• Food & Beverage: Industrial imaging cameras can be used for quality control and safety inspection.
• Consumer Goods: Industrial imaging cameras can be used for packaging and labelling verification.

Each of these industries has different requirements. But all share the need for fast, accurate and reliable inspection.

Key Features To Look For

Not all industrial imaging cameras are created equally.

There are several important factors to consider when evaluating potential cameras for your specific operations:

• Resolution. The higher the camera resolution, the smaller the defects it can detect.
• Frame Rate. Higher production lines require cameras with higher frame rates to ensure each product is clearly in focus.
• Environmental Rating. Ensure the camera can withstand the environmental conditions present in your facility, including dust, moisture and temperature.
• Integration. The camera must integrate with your existing systems, PLCs, software and network infrastructure.
• Lighting Compatibility. Proper lighting is crucial for obtaining quality images. Ensure your camera is compatible with your lighting setup.

Industrial Imaging: Getting Started

Ready to level up your quality control?

Follow these simple steps to get started with industrial imaging cameras:

• Start by defining your biggest quality challenges. Where are the defects in your process? Where do you see inspection bottlenecks?
• Next, establish your specific requirements. What is your required resolution? How fast does your production line run? What environmental conditions must your camera be able to handle?
• Then, evaluate your options. Compare the available cameras and solutions based on your specific needs. Don’t simply buy the most expensive camera. Buy the camera that is the best fit for your requirements.
• Finally, plan your integration. Work with your team to ensure a smooth integration and deployment. Training and support are critical for success.

You can see the huge size of the market by the fact that quality control accounts for 42% of the machine vision market.

If smart manufacturers are investing in industrial imaging cameras then it is time you considered it too.

In Closing

Industrial imaging cameras are a game-changing technology that is transforming how manufacturers and industrial companies approach quality control.

They offer many benefits that are simply unobtainable through manual inspection, including:

• Detection accuracy of over 99%
• Continuous operation, without breaks or fatigue
• Quick returns on investment, typically under 18 months
• Complete consistency, day and night, with every product

Industrial imaging is no longer an emerging technology. The costs have come down significantly and the applications and suppliers have matured.

The benefits speak for themselves.

Whether you are in the automotive industry, the electronics industry, the pharmaceutical industry, the food and beverage industry, or any other industry that requires high levels of quality control…

Industrial imaging cameras can help you catch more defects, reduce waste and deliver better quality products to your customers.

The only question is how long can you afford to wait?