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Case Studies

Vision Systems
LumiTrax™ technology provides a clear advantage for this industrial inspection and assembly equipment manufacturer

Vision Systems
Global food supplier chooses KEYENCE's LumiTrax™ image capture system to assure food quality on its high-speed production line.

Measurement System
LISI MEDICAL’s plant in Miribel, a French town just outside the city of Lyon, specialises in the outsourcing of surgical implants and ancillary items. Consisting primarily of plates and screws, these parts require precision manufacturing and are inspected by the plant’s metrology department. The typical tolerances are in the order of 0.1 to 0.05 mm.

Measurement System
The renowned jewel-bearing specialist uses KEYENCE’s IM Series Instant Measurement system to improve the repeatability and rate of its inspections.

Safety Light Curtains
Continental Corporation, a leading firm in the manufacturing of electronic car components, has always made extensive use of these safety devices in its plants, especially in areas where moving components could injure operators.

Measurement System
Thanks to KEYENCE’s IM Series instant measurement system, SPPF’s operators measure the dimensions of extrusions without any risk of variability. As a result, the company has optimize the quality of its products and established processes for analyze production deviations.

Measurement Sensors
Auto Chassis International uses a custom-built tester to finely measure heat distortion on brake discs. The process is made complex by the fact that the discs rotate at high speed while requiring a measurement accuracy of 0.01 mm. KEYENCE´s LK-G CCD laser displacement sensor enables stable detection despite the glowing-hot reflective metal.

Measurement System
Since 1950 Mi-Me has specialized in the production of precision blanked parts: arc welded contacts, assembled parts, co-molded parts, etc. exported to major markets worldwide.

Optical Micrometers
Possehl France SAS is a company that specializes in precision cutting and stamping. Thanks to its new TM-3000 optical micrometer from KEYENCE, it can now conduct very detailed inspections of every single part it produces.

Displacement Sensors
Piston rings at PSA are inspected using an automated system. Since being fitted with KEYENCE laser displacement sensors a few years ago, the system makes accurate and detailed on-line measurements.

Displacement Sensors
For the past few years Renault’s site in Cléon, France has been using KEYENCE’s LJ-G laser displacement sensors on its G9 engine production line. The site chose the sensors for their detection capability, reliability, and ease of use.

Optical Micrometers
To provide high-speed, high-accuracy inspection facilities for production of a new range of vials, Capitol Europe has opted for KEYENCE optical micrometers in the TM-3000 series. Example of

Displacement Sensors
Duhamel DTI has designed a bench for testing the magnetic circuits of electrical contactors that uses the LJ-G Series 2D laser displacement sensor by KEYENCE. The resulting performance is extraordinary - a rate of 4,000 to 5,000 parts per hour with micron level accuracy.

Displacement Sensors
Tata Steel Europe (whose former name was Corus) is the second largest steel producer in Europe. The parent company, Tata Steel is one of the top ten steel producers in the world. The total capacity of crude steel Group, which employs about 80,000 people on four continents, is over 28 million tons. Tata Steel Rail Division France has 508 people for a production of 456,000 tons of rails and sleepers in 2009. This division has over 150 years of experience in the rail. The products are designed for high-speed lines, conventional networks, heavily loaded routes, metro and urban tramways.

Measurement System
Schnöring GmbH was founded in 1925 by Karl and Ernst Schnöring as a manufacturer of technical springs. To this day, this innovative company located in Schalksmühle, is still a family business, now in its third generation. In the 85 years of the company’s history, it has acquired a wealth of experience and know-how in the field of springs, stamped and bent parts, and assemblies. It now applies this to the manufacturing and development of high-precision, high-quality products. Customers benefit from Schnöring´s proven, made-to-measure, and economical solutions gained from working effectively with the customer.

Measurement Sensors
Fresenius Medical Care SMAD uses a smart system to handle uneven stacks of dialysers. This system consists of a robot that uses two 2D sensors to detect the position of dialysers and move them to a conveyor without any human intervention 24 hours a day, 7 days a week.

Measurement System
Aerospace manufacturers demand the highest precision – even down to the smallest bolt. Fastener Depot Inc. in Diamond Springs, California, is a privately held distributor of inserts, fasteners, and electronic hardware that specializes in unusual and hard-to-find items for high-tech OEMs in the aerospace and defense sectors. The company fills the needs of this niche market by placing the utmost priority on its inspection and quality processes.

Safety Light Curtains
By using KEYENCE safety light curtains instead of hard guarding, Bosch has both increased efficiency and decreased cycle times.

Measurement System
Multi-tools are made up of many parts, and Image Dimension Measuring Systems make inspecting them all faster and easier.

Machine Vision System
Johnson & Johnson’s Health and Beauty site in Sézanne, France, quickly set up a detection system that reliability problems.

Digital Microscope
Thermocoax meticulously inspects the quality of all its mineral-insulated cables. KEYENCE’s VHX digital microscope is part of a powerful arsenal of instruments the company uses to check every characteristic of these high-tech cables.

Measurement System
Timex is America's leading watchmaker and is present in more than 80 countries. Fralsen, its French entity, makes watch movements and used contact sensors and conventional comparators and was looking for a way to improve their inspection process.

Barcode Readers
Food product distributor depends on KEYENCE scanners to load trucks quickly and efficiently, with productivity gains setting the stage for the next phase of company expansion.

Measurement Sensors
By using KEYENCE’s LJ-G sensor, the Automotive Equipment Manufacturer has automated its inspection of airbag deployment slits in vehicle dashboards. This resulted in stable measurements and a fast return on investment.

Machine Vision Systems
The BIC brand is one of the most recognized in the world with presence in more than 160 countries on all continents for more than 60 years. Several quality control inspections are performed on their razors, and BIC was looking for a vision system that could overcome their current issues while keeping up with high production rates.

Digital Microscope
GGB is the world's leading manufacturer of high-performance, self-lubricating and pre-lubricated plain bearings, with more than 1,000 employees globally. To support its product development, its R&D departments in France, Germany and the US have each invested in KEYENCE's VHX-1000 digital microscope to obtain better 3D visualizations of their product under high magnification.

As the market leader in digital microscopy, KEYENCE Corporation has been recognized by R&D Magazine for its developments in the field of microscopy and awarded with an R&D 100 Award. Regarded by many as the “Oscars of Innovation”, the R&D 100 Awards acknowledge and showcase the top 100 technology products of the year.

The Problem: Tribology is one of the main focal points of scientific research at the Institute for Materials Science II. On the one hand, this research is comprised of the application-specific development of suitable tribo-materials for functionalisation of their surfaces by laser-assisted surface engineering methods. On the other hand, the research at IWK II focuses on developing models for characterizing the friction and wear behavior of material pairs.

The Problem: The automated tray loader will occasionally load a tray improperly on the conveyor track. This misloaded tray eventually crashes the production line creating downtime, machine damage and potential danger for operators.

The Problem: The operators switch between jobs to keep fresh, however some components are not always placed onto the assemblies. This can create several scenarios. The first is that the assembly damages parts within the automation equipment.

The Problem: Gauging was performed using hand gauges, contact-type gauges, or some other less accurate indirect methods. Having no standard developed practice, workers at the plant were not taking reliable measurements.

The Problem: Each medical cartridge in the nest must contain only one bead of blood. What was happening is the cartridge would get by with no bead in it or more than one. All of these beads are forced down a tube by air.

The Problem: The customer runs a continuous web of material through their printing presses and would like to run uninterrupted for a full 24 hours per day of manufacturing time. Ideally, the only downtime they expect is a manual change of rolled material when the previous roll is exhausted.

The Problem: It was determined that there were two major problems with the current method of measurement.
- First, the measurements being done by hand were very inconsistent. The material being measured was not rigid, and thus the measurements varied as the amount of force applied to the micrometer by the operators changed.
- Second, the process problems that caused the thickness variation occurred very quickly, and the current “spot checking” method uncovered the problem often times too late. Thousands of dollars worth of “out of spec” material had been produced, only to be scrapped.

The Problem: Sensing the diaphragm is difficult with conventional methods due to the change in color of the rubber and powder coating that can often occur. There is a noticeable height change when the gasket is present, but since the rubber is flexible it can vary from 2-5 millimeters off the base of the unit.

The Problem: Stand-alone style terminals have touch screen panels that act as the interface between the customer and the machine. They needed a way to alert the Kiosk when a customer approached the machine. This would enable the machine to “shut down” during periods of inactivity. This shutdown would have numerous cost savings through the life of the machine.

The Problem: The customer could not stop the line due to the sintering process or the time needed to cure in the oven. Due to the time interval in between the measurements, sometimes good product had to be thrown out along with the bad, costing production time and money. Calipers could potentially damage the product and the readings were inconsistent from shift to shift.

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