Real-Time Visual Inspection of Ingot Defects for the World’s Second Largest Integrated Zinc-Lead Producer

Problem

The world’s second-largest integrated zinc-lead producer faced significant challenges with its ingot production process. With a high production rate of 600 ingots per hour, manual quality control (QC) became impractical and hazardous for workers. The company needed a solution to efficiently and safely inspect ingots for defects in real-time. 

Approach

To overcome the challenges, the company implemented an automated system using cutting-edge computer vision technology. The system was designed to capture defects at high speed, enabling real-time tracking of ingots. Leveraging SAP Business Technology Platform (BTP), a cloud-based deployment, the company ensured seamless scalability and integration with its existing infrastructure. 

Benefits

• Real-Time Defect Tracking: The implementation of the automated system allowed for real-time defect tracking, enabling immediate corrective actions to be taken. 
• Improved Insights: The system provided enhanced insights into raw material quality and production processes, leading to better control over operations and improved efficiency. 
• Live Link with Finished Goods: The solution established a live link with finished goods issuance, optimizing supply chain management and ensuring timely delivery of high-quality products to customers. 
• Enhanced Safety: By eliminating the need for manual quality control, the company improved worker safety in the ingot production process. 
• Increased Productivity: The automated system streamlined the inspection process, resulting in increased productivity and reduced inspection time. 

Overall, the implementation of the automated system with computer vision technology brought significant improvements in ingot quality control, safety, and production efficiency for the zinc-lead producer.