Wienerberger needed superior brick slip quality control to lead competitively. Faktion, with partners Keyence & Datasar, implemented an AI computer vision system. It automates precise dimension checks, classifies quality grades, integrates robotic sorting & generates data for optimisation.
In the world of building materials, the difference between industry leadership and mere survival often lies in the ability to innovate. Wienerberger, a world leader in brick manufacturing, has a long history of embracing cutting-edge technology and strategic partnerships to stay ahead of the curve. The company’s dedication to excellence has given rise to unique offerings such as ready-made brick slips, distinguishing them from competitors.
However, maintaining a competitive edge in an increasingly price-sensitive market requires relentless innovation. Wienerberger’s drive to continually refine its manufacturing process and enhance product quality reflects its commitment to industry leadership and sets a standard for others to aspire to.
The manufacturing of brick slips is an intricate process where even a 1mm variance can mean a significant difference in quality. With categories A, B, and C defining the quality of the bricks (with A being the highest). Ensuring qualitative output through precise brick slip dimensions is a crucial and complex endeavour.
Wienerberger understood that success in this area would require a technological solution, aligning not only with their current production requirements but also adaptable enough to evolve with future industry trends.
Wienerberger's long-time partnership with Faktion became the cornerstone of the solution. In the past, these two companies have collaborated on process optimisation projects that led to significant energy consumption reduction, enhancing sustainability and efficiency.
Wienerberger engaged Faktion, which leveraged its ecosystem of complementary partners. Keyence came aboard as the hardware partner, providing the necessary technological backbone, and Datasar Automation was chosen for installation and industrial automation, contributing their extensive experience in seamless system integration.
In brick slip manufacturing, even a 1mm variance significantly impacts quality and limits downstream use for off-site manufacturing/prefab building. We required an AI-driven inspection system tailored specifically to our manufacturing standards, leading to improved precision and operational excellence.
The solution was a cutting-edge computer vision quality control system, where Keyence provided the vision hardware, and Faktion handled specification, training and configuration. Datasar Automation was responsible for setup, integration, and maintenance. The AI-driven approach meant that the system was more than just a mechanical solution. It provided insights and continuous learning, allowing for constant improvement and optimisation. By harnessing the power of machine learning and data analytics, the team built a computer vision system that inspected the brick slips dimensions in search of deviations from the predetermined values. The system was not only capable of detecting quality inconsistencies but also learned from them, enhancing its efficiency over time.
Automated measurement and classification of brick slips with computer vision, detecting even minimal deviations (as from 0,1mm), ensuring quality consistency across product categories A, B, and C
Seamless integration of the inspection system with a PLC and Fanuc robotics, automatically sorting brick slips according to quality classification, streamlining the production flow.
Utilising visual inspection data to identify upstream process inefficiencies, enabling proactive adjustments and continuous improvement of manufacturing operations.
Automated measurement and classification of brick slips with computer vision, detecting even minimal deviations (as from 0,1mm), ensuring quality consistency across product categories A, B, and C
Seamless integration of the inspection system with a PLC and Fanuc robotics, automatically sorting brick slips according to quality classification, streamlining the production flow.
Utilising visual inspection data to identify upstream process inefficiencies, enabling proactive adjustments and continuous improvement of manufacturing operations.
Within a project lead time of just 3 months, the vision system went live, including the design and installation of top-down cameras, background LED lighting, defect rejection for C quality, and integration with a Fanuc robot to separate A and B quality brick slips. This, however, is just the beginning. The vision system's classification data will be used to analyse root causes in the upstream process, a clear indication of how data-driven manufacturing can lead to consistent improvements. The speed and efficiency of the implementation are testaments to the synergy between Wienerberger, Faktion, Keyence, and Datasar Automation, reflecting a shared commitment to excellence.
By leveraging an advanced computer vision and AI solution, Wienerberger has enhanced manufacturing precision, optimised product quality, and strengthened its industry-leading position in building materials.
This successful implementation sets a new standard in smart manufacturing and maintenance. It highlights how data-driven and AI approaches are not just the future but the present of the manufacturing industry. Wienerberger's decision to collaborate with Faktion and its ecosystem of partners has positioned them to outcompete in a market where price is paramount. This collaboration is a testament to their forward-thinking approach and a model for others in the industry to follow. By leveraging technological innovation and embracing collaborative partnerships, Wienerberger illustrates the transformational impact that strategic decisions can have on a traditional industry.
The success of this project with Faktion, Keyence, and Datasar Automation solidifies Wienerberger's leadership in the building materials industry. This endeavour highlights a roadmap for innovation, cooperation, and leadership that resonates far beyond the brick manufacturing industry, providing insights for companies seeking to excel in an ever-changing business environment.
.png)
