TATA
STEEL
EUROPE
USE CASE

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|  Higher quality, reduced risk

Manufacturing operations aim to deliver the highest quality during the production or assembly process. Over half of quality checks involve visual confirmation to ensure parts are located correctly, have the right shape or color and are defect free. The pickling line is the last step before steel is sold to the market, therefore at each of the five round-the-clock shifts a human inspector continuously monitors the strip after pickling. Surface defects are flagged and determined according to the type of defect, resulting in inefficient, manual, work in a hazardous environment.

The earlier issues are detected and more frequently they are checked, the better they can be addressed, reducing emergency repairs that shut down machines and cause customer dissatisfaction. By automating visual quality inspection manufacturers will save time and money and improve customer satisfaction.

“BrainCreators were always open and transparent about intelligent automation, only promising what they could achieve without the usual hype stories about AI”

- Johan Bernard, Manager Process Engineering, Tata Steel Europe

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PERCEIVE

The Digital Steel Inspector looks at nearly 50 million images per day. Images are taken at fast intervals by an array of camera's on the line.

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DECIDE

The digital inspector automatically detects the highest priority defect classes, applying a continuous learning loop to extend its capabilities.

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RESPOND

The inspector's output directly triggers the correcting of defects, adjusting of quality-based pricing, and halting machines in case of danger, preventing downtime.

|  Digital Inspector for Steel production

Digital inspectors run and learn on our BRAINCREATORS AI Platform which contains an intelligent learning module powered by active learning. This greatly reduces the burden of creating examples to learn from, only selecting the most informative defects for the classifier. This effectively solved the so called “needle in the haystack” problem that inspectors were previously faced with.

  • Improving prediction accuracy, consistency and real-time results across a range of products
  • Eliminating quality problems at the edge
  • Decreasing the number of checks performed by experts
  • Increasing worker safety and their ability to comply with ever changing health and remote working regulations
  • Running production 24/7 without interruption
  • Ease of use with a 100% browser based user interface, shortening time to value
  • Increasing customer satisfaction

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|  Challenges

  • Human inspection requires a high level of expertise, but skilled experts are becoming very scarce
  • Inspecting the production line 24/7 without ever looking away is impossible
  • There often is no consistent overview of product quality, causing customer returns and refunds

|  Solutions

  • Automated monitoring of the production line without any interruptions
  • Multi-camera interpretation for additional accuracy under different angles
  • Triggered responses to prevent downtime or more severe damages

|  Benefits

  • Real-time error detection on the production line without a human expert on the floor
  • Faster computing capabilities allowing a production speed increase
  • An accurate overview of detected defects rendering an overall quality assessment
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