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Surface Inspection of Sheet Metal Parts with ABIS II at KIA Slovakia
Since 2006, Kia Motors Corporation have been operating at their first European production premises in Slovakia, thus having established new standards in automotive manufacturing with their modern industrial facilities. At Kia Slovakia, the main emphasis has been put on criteria such as highest quality and efficiency within every single production stage.
Using the optical inspection system ABIS II from Steinbichler Optotechnik, the surface quality of the produced sheet metal parts (panels) is thoroughly tested in immediate vicinity of the stamping line. The highly accurate and fast ABIS II sensor system reliably detects even the smallest relevant surface defects such as dents, bumps, sink marks, waviness, constrictions and cracks etc. with a defect resolution down to 10 µm.
By carrying out selective random measurements, a continuous quality control is guaranteed. Additionally, increased frequency of test measurements at production start lead to important conclusions on the production process (e.g., the influence of tool modifications on the manufactured parts). With these results, Kia Motors Corporation is also able to coordinate their quality control processes between the different production sites. This further helps to achieve the challenging corporate standards summarized in the company´s key goal "Drive Defects to Zero".
The ABIS II system is easy to operate and is equipped with a high-performance software for the system control and result evaluation which enables a highly effective surface quality inspection. The integrated classification of the measurable defects represents an essential part of the data evaluation and builds the basis for an automatic application of the corresponding quality criteria in the following decision processes. With the ABIS analysis system software, defect characteristics and severity classification (based on auditor experience) can be generated – not every defect is relevant and has to be repaired. The detected and classified surface defects are color-marked on the screen display of the test part. Also, a texturized version (simulation of a ground-off test part, i.e. virtual use of grinding stone) is realized.
Using the ABIS II system within the first steps of the process chain (e.g., in the stamping line), a significant cost reduction for quality control measures can be achieved because time-consuming, and thus, expensive rework or rejected parts can be avoided.
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