Enhanced product quality and production efficiency through application of real-time automated inspection

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Polycon is a major automotive plant located in Guelph, Ontario. The plant is one of Magna Inc. plants and specializes in manufacturing polymer based body parts like fascia and has around 1400 employees. A critical measurement of quality is that all shipped parts must be free from defects. Defects come in various forms and characteristics but can generally be categorized in three categories: physical, appearance, and colour matching defects. Appearance defects are defects that impact the overall look of a finished product such as orange peel (the surface of the part looks like the skin of an orange). Physical defects include any physical damage to the part surface including paint application defects such as edge drips and paint runs, dirt or fiber on the part, handling defects like bumps, nicks, scratches, gouges, and finally moulding defects. Colour matching defects are defects where the part's colour measurement doesn't meet the customer specification.