What do the definitions say:

Control: To examine something to check its quality, its proper functioning.

Sort: To treat in such a way as to remove what is bad.

In the case of Control, the objective is to obtain information on the conformity of a part or component.

In the case of Sorting, obtaining information on compliance will lead to a classification action between compliant and non-compliant parts with a separation of the different populations.

In addition, unlike Control, which can be carried out in the form of sampling, Sorting induces exhaustive examination on each piece of a batch. This is why TQS has been working for more than twenty years to automate these sorting operations, which can be applied to millions of parts.

Only one goal #Zerodefault!

Any metrology device has its own uncertainty. It is large depending on the technology and the scale of the object being measured. This uncertainty materialized by the variation in the value restored when several measurements are taken successively. In some cases, the way the measurement is made will influence the outcome.

Regarding automatic sorting, other factors will influence the value returned, the position of the part, its spacing in relation to the others, the cleanliness of the parts checked, etc. The combination of these influential factors will in several cases prevent the measurement from being carried out in good conditions. The objective being the #Zerodefault, these cases will generate what is called False Scraps.

These parts are therefore discarded for safety, but without being sure of their non-compliance. To limit the impact of these False Scraps on the result, at TQS the discarded parts pass through our machines three times. Thus, we drastically reduce the rate of False Scraps.

The aggravating factors in the case of False Scraps concern the part being tested itself, but also the inspection environment.

Among the factors concerning the part is the expected measurement accuracy (the tolerance interval) regarding the capacity of the available material. We also find the typology of defect. For example, if it is an aspect control, the very definition of the acceptable limit is more complicated to establish. This subjectivity will inevitably generate False Scraps. To significantly improve these problems, it is essential to define the right combination between the equipment used and the need for control in advance. It is also imperative to define the limits of each appearance check with parts that are representative of the defects. As far as possible, it is necessary to anticipate variations in the appearance of the parts (e.g. the different surface treatment baths), this will allow a better configuration of the control tools.

In the inspection environment, various factors will have a particular influence: the repeatability of the position of the part at the time of inspection, the cleanliness of the supports and measuring tools as well as the part itself. The improvement actions will therefore consist of:

_Anticipate a feeding and positioning system adapted to the shape of the part and the expected speed.

_Clean the media and measuring devices regularly or continuously (as is the case in some cases at TQS). Care must also be taken not to waste on batches of parts that are too polluted, for example with oil or shavings.

These best practices will significantly improve the rate of False Scraps while maintaining our objective of #Zerodefault dear to TQS.

Increasingly, Automatic Sorting is integrated as a step in the manufacturing process of unit parts. It is therefore most often assumed by component manufacturers (bar turning, cold forming, cutting, plastics processing, etc.). But who really benefits from this very technical operation?

The primary objective of this operation is the fluidity of assembly. So, the first beneficiaries are the equipment manufacturers who assemble these components.

Secondly, the beneficiary will be the end user, as he or she will be guaranteed a functional, safe and durable device.

For equipment manufacturers, the benefit revolves around 3 axes:

1. Quality improvement: 100% sorting ensures that each component meets the required tolerances and quality standards. This reduces the risk of failure or variations in production processes, ensuring stable and reliable performance of final products. For OEMs that depend on precision and durability, this is essential to meet the stringent requirements of the automotive industry, for example.
2. Reduction of production and after-sales costs: Although the initial cost of 100% sorted components may be slightly higher, this investment translates into a significant decrease in indirect costs. Quality products reduce the need for returns, warranty repairs, and recalls, which can result in significant financial and reputational costs. In addition, a less disrupted production line means fewer line stoppages and increased productivity.
3. Strengthening customer satisfaction and brand image: By integrating perfectly sorted components, OEMs can guarantee more reliable end products that meet the quality expectations of their customers (car manufacturers, perfumers, watchmakers, etc.). A better reputation for reliable components can facilitate business relationships and increase customer trust, thus fostering new opportunities and retaining existing partnerships.

Automatic sorting can bring significant benefits to the cosmetic bottle industry by improving product quality, optimizing costs, and meeting sustainability requirements. Here’s how:

1. Improved quality and reduced defects: Automatic sorting uses advanced technologies like machine vision and high-precision sensors to identify and eliminate defects (scratches, bubbles, impurities) that could adversely affect the appearance or functionality of the vials. This precision ensures products that meet the high standards of the cosmetics industry where aesthetics play a crucial role. These technologies can also be applied to the pump part of the vials by controlling the different parts that make up the mechanism.
2. Increased efficiency and reduced labor costs: Unlike manual sorting, automatic sorting can operate continuously, reducing production costs and downtime. Thanks to the speed and precision of the machines, companies can process a large volume of vials in a short time, which optimizes yield and allows them to better meet peaks in demand, especially in a context where recruitment is complicated.
3. Compliance and traceability: Automatic sorting systems are often equipped with software that allows precise data to be recorded on each batch of vials, facilitating traceability. If something goes wrong, it’s easier to identify the causes and take quick corrective action, ensuring compliance with quality and safety requirements.
4. Reduced waste and improved sustainability: Automatic sorting systems help minimize waste by ensuring that only compliant vials are routed to the next stages of production. Defective vials can be identified quickly and redirected as early as possible in the value chain.

In conclusion, automatic sorting allows cosmetic packaging companies to improve their competitiveness while ensuring products of consistent quality, meeting the expectations of cosmetic brands and end consumers.

The assemblies of Consumer Goods are major consumers of automation, and large series require significant productivity gains. In this context, it is essential to have perfect control of the components that are injected into the assembly lines. What are the benefits of using Automatic Sorting to ensure component compliance?

1. Reduction of defects in production
   Sorting components before assembly ensures that only compliant and defect-free parts are integrated into the final products. This significantly reduces the risk of defects during assembly, which limits production line interruptions, product returns, and warranty repairs.
2. Improved quality and brand reputation
   Higher quality end products through component sorting increase the reliability of consumer goods on the market. A good reputation for quality helps build customer loyalty and open up new business opportunities. More reliable products also reduce the need for post-sales technical support, which can be a strong argument with end customers.
3. Optimization of production costs
   Although sorting can be an upfront cost, it is a worthwhile investment, as it avoids larger expenses related to defects in production. For example, high-quality products reduce the costs of returns, rework, and defective parts management, while increasing productivity by avoiding line interruptions.
4. Increased productivity
   Eliminating non-conforming components prior to assembly reduces the risk of delays or adjustments during the line. Production lines can operate at full capacity without being slowed down by quality issues, allowing for better resource utilization and yield.
5. Alignment with standards and certifications
   In many consumer goods industries, quality standards are strict, and certifications are required. By incorporating rigorous screening upstream, manufacturers ensure that they meet quality and safety standards, simplifying the audit and certification process, and reducing the risk of penalties or non-conformities.
6. Access to new automatic sorting technologies
   Sorting can be carried out using modern technologies (artificial vision, artificial intelligence) that ensure high accuracy and detection of defects that are difficult to spot with the naked eye. The use of these technologies not only increases the quality of sorting, but also collects valuable data on defect rates and causes, helping to continuously improve manufacturing processes.

The feedback from automatic sorting is a valuable source of data that can enrich and optimize the Product FMEA (Failure Mode, Effects and Criticality Analysis) analysis by offering a detailed view of the actual defects encountered, failure trends and potential areas for improvement. Here’s how it can be effectively integrated into the Product FMEA process:

1. Identification of real and recurring failures
   Automatic sorting records the types of defects detected in components, such as scratches, cracks, dimensional defects, or material defects. This data makes it possible to accurately document the actual failures encountered by identifying not only visible defects but also those that could be the source of functional failures. This clarification enriches FMEA by providing concrete and verified examples of possible failure modes.
2. Evaluation of the criticality of defects
   Thanks to the statistics provided by the automatic sorting, it is possible to quantify the frequency of each type of defect. In an FMEA, this information allows for a better assessment of the criticality of each failure mode based on its actual probability of occurrence. For example, if certain defects appear consistently and impact performance, they may be deemed more critical and given a higher priority in analysis and corrective actions.
3. Optimization of potential causes and checkpoints
   Feedback from automatic sorting often highlights the production areas or manufacturing steps that are most prone to errors. This information can be used to enrich the “potential causes” section of the FMEA by specifying the processes or materials responsible for the defects. It also allows for the definition of more specific control points and enhanced oversight where the risk of failure is highest.
4. Improvement of corrective and preventive action plans
   Automatic sorting data provides real-time feedback on corrective actions taken. If a process or material change decreases the defect rate, this is concrete evidence of the effectiveness of an action plan. This information can be fed back into the FMEA to adjust or validate preventive actions, thus enabling a cycle of continuous improvement based on evidence.
5. Feedback for product design
   Automatic sorting helps to identify defects that are most difficult to avoid or correct. If certain defects recur frequently and are related to design choices, this information can be shared with design teams to rethink certain product characteristics (shapes, materials, tolerances) to minimize the risk of failure by design.
6. Improved documentation and traceability
   Automatic sorting systems record all defect data, providing detailed documentation that can be integrated directly into FMEA analyses. This documentation, kept in a structured and accessible manner, makes it easy to track FMEA improvements and revisions over time, providing accurate traceability of quality progress.

In conclusion, feedback from automatic sorting results in a more accurate, factual, and responsive Product FMEA, resulting in higher quality products, reduced defects, and continuous optimization of production processes.

While Automatic Sorting and Manual Sorting are often opposed, they are both complementary activities, each with its own fields of application. What are the advantages and disadvantages of each?

Manual sorting: It offers flexibility and can adapt to variations or unique situations. Its initial cost is low since it only requires operators, but it depends on human concentration and endurance, for example it becomes very complicated when it is necessary to control several criteria at the same time. Manual sorting is slower and error-prone, especially for large volumes, but it is still relevant for specific or small-scale operations.

Automatic sorting: This type of sorting uses machines and systems that are programmed to process large quantities quickly and accurately. Although the installation is expensive, it allows constant sorting without pauses, with a guarantee #Zerodefault on the controlled criteria. However, automatic systems are sometimes less suitable for unforeseen situations or special cases, requiring manual adjustments or reprogramming.

Conclusion

Manual sorting is suitable for small volumes and tasks requiring human flexibility. Automatic sorting, on the other hand, is suitable for large flows with standardized criteria and allows for fast, efficient sorting, but at a higher initial investment cost. The TQS service offer allows you to benefit from the advantages of Automatic Sorting with a #Zerodefault guarantee without having to bear the initial investment. This solution therefore becomes accessible at a reduced cost, even for smaller quantities and one-off cases.