Quality control & assurance

Nearly any industrial enterprise has to deal with multiple layers of checks to ensure certain quality standards are met, both in terms of in-house products, but this likewise applies to items received from suppliers.

Quality checks are critical and integral to product delivery, having an enormous impact on subsequent processes, safety and customer satisfaction. Processes, such as, incoming material inspections, in-process quality control or final product inspections are just some of the checks that are performed, often on a daily basis.

The above-mentioned items are carried out in various ways, ranging from a simple visual control, heavily relying on human-factor, to paper checklists, digital video cameras, smartphone or tablet applications, to complex setups with cameras and AI performing the checks fully autonomously.

Extended Reality offers a fresh, unique approach to quality control overall, with notable improvements in speed, accuracy and traceability, while not being overly pricey, offering a middle-ground solution. Depending on the level of digitalization already present in your quality control processes, you can select from multiple types of technology, depending on your preferences and desired outcome.

In terms of extended reality, there are 2 approaches: 2D vs. 3D checks, each comes with pros and cons and differing levels of utility for the process in question:

2D checks, also known as „assisted reality“, are typically process maps of screens containing text, photos or videos, each guiding the inspector during the process step-by-step. At the same time, the inspector collects data while performing the task. This can be carried out on smart glasses, smartphones or tablets. The benefit of using smart glasses in this scenario is having free hands, and going through the process using voice commands. Additionally, several types of accessories can be utilized, such wireless scanners, thermal cameras, boreoscopes and torches. The data from these workflows is then collected and made available for later use, typically in a PDF format.

3D checks, utilizing „augmented reality“, offer a more immersive, hands-on experience where a 3D CAD model is overlayed onto a real product, allowing the inspector to directly compare the real product to the model and check for any deviations in real-time. Additionally, check scenarios can be created beforehand, showing the inspector what to check exactly and where. This is typically done on tablets, given the nature of the control method, so for instance, the utility of 3D smart glasses and accessories is limited. Data from these check scenarios is saved and made available for later use, typically in PDF format.

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Ultimately, extended reality can slightly alter your existing processes, or can transform them significantly. The scenario preparation likewise varies greatly, and it comes down to process analysis, testing and final implementation, as well as the nature of the process itself. Below are some examples of how XR can be used in different quality control workflows.

Incoming / outgoing quality inspection

When receiving new products or raw materials from suppliers, several criteria may turn out not to be up to required standards, resulting into a plethora of potential issues down the line. For instance, if a defective item passes through to production, you may end up having to perform reworks, restarting the process from scratch, potentially slowing down subsequent processes and raising costs significantly.

If, on the other hand, you are in a position of a supplier, ensuring quality standards according to your agreements with customers may be a strenuous and multi-faceted practice spanning multiple stages of product development and manufacturing. Identifying potential issues or defects before the item leaves your facility, or having proof of quality is often not only required, but is also beneficial for you. You also reduce the chances of a customer potential complaint.

For instance, using assisted reality, we could help you identify the specific product based on a barcode scan, and list the items to be checked in a simple, step-by-step manner, gathering the relevant data and transferring them into your database or other platforms. This could help you trace the faulty product, and give you concrete evidence of the fault, photos or videos included. This report can then be used to keep track of issues internally, or towards the customer, as a proof of quality.

Augmented reality could perform a similar task, but from a slightly different perspective, and with a more hands-on approach to identify and highlight a specific defect.

First article inspection (FAI)

Introducing a faulty item into mass-production is an unfortunate and costly overlook that is not easily fixed, especially if identified too late (e.g. when the product already reached the customer). Whether the problem occurrs during product specification or as a result of faulty machining, the consequences are far-reaching, adding up to delays and costly returns.

Using augmented reality and superimposing the CAD model on the real product can give you a quick and accurate picture of discrepancies, such as dimensions, missing features or even surface defects. Additionally, inspection steps can be created to guide the inspector directly on the real product, reducing the likelihood of the inspector overlooking critical inspection points. A comprehensive report is then generated automatically in multiple languages, making the subsequent reworks or re-designs easier.

Assembly check

Assembling a product in itself may be a notable challenge, but verification of it may be even more so. Whether the item in question comprises of tens, or thousands of parts, delivery of incorrecty assembled product may be life-threatening for the end-users. If the product is missing parts, or the parts are incorrectly affixed, it may cause the product to malfunction, not work as intended or break altogether.

Both augmented and assisted reality can be utilized here. A comprehensive guide can be generated, showing the inspectors what to check step-by-step, and helping them by displaying pictures, videos or other media in their field of view, while at the same time documenting the items one by one, generating a detailed report of how the assembly was carried out.

On the other hand, using augmented reality specifically, assemblers can use a tablet as a means of self-correcting each assembly step. Once they finish assembling a part, they can superimpose the CAD model on the product in question, and they can immediately spot discrepancies, such as missing parts, improving the final quality of the whole product. Primarily though, this technology is used once the assembly is finished.

Body-in-White construction

This process is very well-known and often introduces significant challenges, because correct geometry of parts is a key aspect and a metric of quality. You can imagine a check of parts such as bumpers, hoods or frames. Items such as welding points, defects (such as scrathes), shapes and dimensions are often checked for. Discrepancies or defects in these features will almost certainly end up in costly returns, potentially damaging a relationship with the buyer.

Augmented reality can overlay the expected weld points and patterns onto the physical structure. Inspectors can use this to verify that all welds are in the correct locations and meet quality standards. Additionally, the technology can highlight areas with potential defects, such as misaligned panels or insufficient welds. Inspectors can receive real-time feedback, enabling immediate correction.

Extended Reality offers significant potential to enhance and transform quality control workflows in industrial settings. By leveraging both 2D assisted reality and 3D augmented reality, XR improves the accuracy, speed, and traceability of quality checks. These technologies provide detailed, real-time guidance and verification, enabling immediate correction of errors and ensuring higher standards of quality.

Implementing XR can streamline processes such as incoming material inspections, first article inspections, assembly checks, and body-in-white construction. XR tools can reduce the reliance on human factors, minimize errors, and provide comprehensive documentation, leading to better overall efficiency and product quality. As a versatile and cost-effective solution, XR can either slightly alter or significantly transform existing quality control processes, depending on the level of digitalization and specific needs of the enterprise.

Quality control & assurance

In terms of extended reality, there are 2 approaches: 2D vs. 3D checks, each comes with pros and cons and differing levels of utility for the process in question: