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【2024 Application Example】 AI-Based PCBA Surface Defect Detection Improvements

With the introduction of theAOI+AIWith the introduction of the system, we can improve product yield, reduce costs, and from a business perspective, increase customer trust and sales revenue. Moreover, AIit has advantages that are difficult to imitate, unlike other equipment that can be bought with money, making it hard for our competitors to catch up with us.

Our company's current development

We are committed toIOTsmart manufacturing; our systems already include smart materials systems, environmental humidity control systems, anti-miscarriage systems, smart procurement computation systems, smart inventory systems, solder paste management systems, and production management systems. We have asked other manufacturers about the possibility ofAIinspectingPCBAsurface defects, each hoping that we would purchase their equipment, but none were effective upon verification. After discussing with IT service providers, we defined it asAOI+AIa feasible operational model.

Tzuhong Technology has invested inAOI+AIan inspection plan to checkSMTtext on components, solder joints, polarity, missing parts....and usingAIto replace manual learningAOIand define the 'potentially defective' parts, enhancing productivity and reducing misjudgment rates.

Industry pain points

    Taiwan faces a severe labor shortage, especially those willing to perform visual inspections are few and typically older, increasing the frequency of missed inspections. Thus, the most critical bottleneck in the pursuit of high-quality electronics has become post-production inspections. Previous consumer products with undetected anomalies were acceptable within a certain ratio. However, in the automotive industry today, undetected defects could lead to fatalities; hence, the automotive industry has extremely high quality demands. To survive in the automotive supply chain, we must address the issue of undetectable anomalies.

    Moreover, as wages in Taiwan continue to rise, we can only endeavor toAIreplace traditional manpower with technology, otherwise, even if the anomaly leakage problem is resolved, the relatively high labor costs will still prevent competitiveness in this industry.

Application technology and explanation

    Initially,(Figure 1)PCBUpon emerging,Reflowsystem, it will undergoAOIwill undergo inspection, dividing into 'suspected defective' and good products. At this point, the 'suspected defective' portion accounts for20%manual review for these20%parts, further classifying the 'suspected defective' portion into good and defective products. With

    We aim to leverageAItechnology, to shift from manual re-inspection of these20%technology, we aim to replace manual review of 'suspected defective' products withAIand after review, the results still yield 'good' and 'suspected defective' products, but now 'suspected defective' comprises only3%thus reducing the workload of Tzuhong's employees from20%down to only3%In theory, it isAOIIn theory, after inspection, it is further reviewed byAIbut it appears to go throughAOIonly, so we call this technologyA0I+AIDetection(Figure 2)

The original AOI inspection process
The original AOI inspection process

The operator will place the testPCBboard intoAOIthe inspection equipment, outputtingAOI

information on defective products, then manually re-inspect one by one to determine if they are defective.

AOI+AI inspection process
AOI+AI inspection process

The operator will place the testPCBboard intoAOIthe inspection equipment, outputtingAOIinformation on defective products after,

then proceed byAIfirst performingAOIre-assessment of defective products, outputtingAIinformation on defective products afterward,

then manually re-inspect one by one to determine if they are defective.

Process differences

    By introducing theAOI+AIsystem, not only can we enhance the efficiency and yield of visual inspection personnel, we also have this timeAIexperience in system introduction, we will also incorporateAIthe use of big data into Tzuhong's existing smart manufacturing systems, further enhancing the performance of our smart manufacturing systems and reducing the pressure on employees.

Difference between pre and post-introduction
Difference between pre and post-introduction

Promotion strategy

(1)       Similar field diffusion: allSMTmanufacturers face bottlenecks in inspections leading to shipment delays; introducing this system can solve the severe labor shortage issue and enhance shipment speed and quality, allowing self-promotion to customers or through equipment dealers to cater to relevant needs.

(2)       Cross-industry expansion plans: negotiate withAOImanufacturers to directly integrateAIthe system intoAOItheir systems, enhancing their market competitiveness.

 

Profit strategy

(1)       In collaboration withAOImanufacturers, collect licensing fees.

(2)       Direct sales toSMTthe manufacturing industryAIsystems.

(3)       ProvideSMTmanufacturing industryAOI+AIsystem subscription model

「Translated content is generated by ChatGPT and is for reference only. Translation date:2024-12-09」

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【解決方案】佐翼科技無人機導入高爾夫球場域 可節省一半人力
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internal and external resources Only then will we be able to gradually achieve the goal of making golf courses smarter and smoothly assist the industry with transformation Zuoyi Technology's CEO, Liu Junlin 「Translated content is generated by ChatGPT and is for reference only Translation date:2024-05-19」

這是一張圖片。 This is a picture.
CCTV Intelligent Video Search System

Search for a specific person, find someone with a suitcase entering the factory in Gao'an area Color features of the person and the object confirmed, person in blue and black top, suitcase in black color, throughCCTV the intelligent video search system, by setting object and color retrieval conditions, it can successfully locate three video clips containing the target subject This greatly aids operational staff in finding the target items, and through this system, search speed can far surpass manual effort6fold Pain Points The CSE-Kaohsiung Plant is densely equippedCCTVto monitor every corner of the plant area, but when an incidenthappens, it's impossible within a limited time throughCCTVvideo playback to find the incident, the implications and risks behind this are self-evident Many areas that are usually unmanned can easily become security blind spots Thus, how to monitor a vast plant area more intelligently and effectively is one of the crucial aspects of building a smart plant for the semiconductor industry The AES Plant in Kaohsiung covers a vast area, with many important sites requiring monitoring of personnel movements to ensure corporate secrets and employee safety 1 Automated production lines and warehouses In semiconductor enterprises’ automated production lines and warehouses, oftenAGV(Automated Guided VehicleAGVs automated guided vehicles travel at high speeds if plant personnel inadvertently enterAGVthe moving area and cannot issue a warning to the person, then the regrettable accidents that occur will be too late to reverse 2 Material and product storage areas Materials used in semiconductor-related processes are costly if areas storing materials or products are breached, there is a risk of loss of high-value materialsproducts 3 High-security areas Trade secrets relate to the core technological competitiveness of semiconductor-related enterprises if someone breaches the high-security areas, there is a risk of corporate secrets being leaked The safety of trade secrets has always been one of the most critical issues for semiconductor enterprises 4 Loading docks At AESLButthe dock area often has loading vehicles coming and going if someone intrudes into the dock area, there is a risk of vehicle collisions and accidents Additionally, goods awaiting shipment at the dock area could be stolen or potentially damaged from collisions, thus causing significant reputation and financial losses for the company, further leading to production and shipping inconvenience When an abnormal event occurs, how to quickly search for the relevant key footage from massive data Many important locations within the AES Kaohsiung Plant need to be equippedCCTVfor safety checks, butCCTVWith thousands to tens of thousands of cameras, manually searching through footage for an event requires laborious frame-by-frame review which is time-consuming and inefficient In light of advancements in computer vision, it's beneficial to utilizeAIto replace manual playback and searching Problem Scenario Object Detection The data source for object detection comprises two parts Open-source datasetsOIDv4and AES Kaohsiung PlantCCTVImage files For these files, search for usable data, specificallyOIDv4image files For these files, extract the defined nine major categories of objects for training data among them, two object categories, knives and gasoline barrels, were not found inOIDv4found usable data for knives and gasoline barrels, while the remaining seven categories of objects are available fromOIDv4useful training data found for the remaining seven categories of objects, all marked Regarding the Kaohsiung PlantCCTVimage files, select some frames Frame of the footage, and manually annotate the objects to be_detected for training and testing data Nine Major Objects Color Recognition The data source for color recognition is divided into two partsInternet image screenshots, and Kaohsiung PlantCCTVimage files Currently, no publicly available open-source datasets specifically for color recognition applications have been found, so images are collected from the web Search the web for images of the defined nine major object categories, save the images after separating the objects from the background, keeping only the object sections, and mark the images according to color Additionally, for the Kaohsiung PlantCCTVimage files, use the already-markedbounding boxextractCCTVimage files from variousFramesections of objects identified by color, and finally, visually identifiable images are marked according to color Each object category has its specific color definition, depending on the usual colors seen in these objects in real life Dynamic Ignore during Training FromOIDv4during the training of the object detection pilot model, since each image in this dataset is only marked for a single category, but the image may contain other desired detection categories unmarked For such cases, dynamic ignore techniques will be employed during training to avoid confusion Next, use the extracted training data from the Kaohsiung Plant toFine-Tuneenhance the detection rate of the object in specific designated areas Finally, select the model that computes the lowest loss value in the test set during the training process as the main object_detection model Dynamic Ignoring AIHelp You View CCTV The intelligent video search system primarily serves as an assistive system for searching surveillance footage, capable of speeding up the process of finding target events by setting search conditions for objects By simply defining the search conditions, you can quickly produce thumbnails of critical objects and playback for review, shortening the time required for manual case retrieval of the past The search time is quickly6doubled, allowing the front-end security unit to use this platform to strengthen the first line of risk management supervision and take timely preventive measures 「Translated content is generated by ChatGPT and is for reference only Translation date:2024-12-12」