Digital Transformation
Casting Quality Inspection and Defect Traceability System
Operators log every NG casting by face, zone and defect type in 10 seconds, tied to its serial number in SQL.
CLIENT
INDUSTRY
SOLUTION
DURATION
The Challenge
Casting defects were found at inspection but recorded inconsistently, often on paper or not at all. Without each defect tied to a serial number, a part face and an exact location, quality engineers could not see patterns, trace a problem back to its process step or prove what had shipped. The plant needed a fast, operator-friendly way to capture every NG casting as a structured record without slowing the line.
Key Requirements
- Scan the 2D code to load the part profile
- RFID badge login for every operator
- 10 part models, 6 faces each
- Up to 120 location zones per face
- 60 dynamically assigned defect types
- Log an NG part in 10 seconds
- Write every record to SQL
- Run 24/7 at line rate
The ICR Solution
ICR integrated a casting quality inspection station that turns every operator judgment into a traceable record. Operators badge in with an RFID reader, and a Keyence SR-1000 scans each casting’s 2D code to load the matching part profile on a Pro-face touchscreen HMI. The operator marks the casting Good or NG. For an NG part, they select one of six faces, tap the exact zone on a grid of up to 120 locations and choose from 60 defect types assigned dynamically to that model. An Allen-Bradley CompactLogix PLC ties serial number, operator, face, zone and defect together and writes the record to a SQL database, while sharing data with the plant’s line data system over Ethernet.
Equipment & Technology
- Allen-Bradley CompactLogix PLC
- Pro-face touchscreen HMI
- Keyence SR-1000 2D code reader
- HID RFID badge reader
- SQL database integration
- Phoenix Contact Ethernet switch
- Keyence photoelectric part-present sensor
Scope of Work
- Integration
- PLC/HMI Programming
- SQL Database Integration
- Installation
- Commissioning
Results
Every NG casting is now logged in 10 seconds with its serial number, operator, face, zone and defect type, and the system runs 24/7 at line rate. Quality teams query SQL for defect patterns by model, face and location instead of reading paper logs, so problems trace back to their source fast. Badge login makes every entry accountable across all 10 part models.