"Designing Vision Systems for Human Operators and Workflows," a Presentation from 8tree
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Transcript of "Designing Vision Systems for Human Operators and Workflows," a Presentation from 8tree
Lisbon Hangar Capacity: 3 WB, 5 NB Hangar Area: 26,380 m² Total Building Area: 71,200m²
Rio de Janeiro Hangar Capacity: 4 WB Hangar Area: 14,500 m² Total Building Area: 180,000m²
Porto Alegre Hangar Capacity: 1 WB, 5 NB Hangar Area: 12,500 m² Total Building Area: 55,000m²
• Leading global provider of heavy-check Maintenance Repair and Overhaul (MRO)
services
• Operations in Brazil and Portugal
About TAP-M&E
www.8-tree.com
The Dent-mapping Problem
Hail Damage Damage due to ground equipment Lightning strike (Image Source: Boeing)
The Challenge The Ideal Solution
Achieve reliable, accurate and objective - Dent-mapping & assessment - Corrosion Blend-out
Real-time. Boosts inspection efficiency
Reliable & Consistently Accurate
Comprehends industry-mandated* tolerances
Instant Answers…not just data
Handheld-portable. Field-friendly. Zero Learning Curve
No Surface Preparation needed
(Image Source: Wikipedia)
* Structural Repair Manual (SRM) details tolerances for Aviation Maintenance industry
www.8-tree.com
What operators demand What operators must tolerate
Ease of use Difficult learning curve
Accuracy Complex tools & menus
Consistency Long interpretation & reporting time
Reliability Subjectivity & Human-error
Operator Experience Today
www.8-tree.com
“Traditional dent-checking methods are very time consuming
and frustrating”
Valter Fernandes
EVP, Operations
TAP-Maintenance & Engineering
TAP-M&E: The Problem Statement
www.8-tree.com
Typical industry format
• Minimal identification data
• Basic numeric measurement values
• Relies on manual entry of location information
• Text-only, unless operator attaches a photograph /
manual drawing of affected area
Dent Reports: Traditional Methods
www.8-tree.com
Tool introduction inside TAP (Oct 2015)
• User training – minimal; intuitive 1-button operation
Integrating the system inside TAP’s workflow
• First-phase = Dent-Mapping
• Next-phase = Corrosion Blend-out, Scratch & Gouge Blend-out
Acceptance by technicians – easy-to-use tool
Implementing @ TAP-M&E
www.8-tree.com
• Point-and-shoot
• Never look away – eyes always on task!
– Go/No-Go Digital Mapping
www.8-tree.com
• Dent-Reporting Tool – Image-based reporting format with traceable measurement values
• Measurement values extracted directly from SRM-compliant dentCHECK results
Dent Reports:
Information Rich Reporting
A / Y (or W / D)
Deepest point x-section
Distance to frame & stringer
Detailed log (operator ID, time-stamp, job #)
Color-coded annotation
Audit-ready digital reporting
Customizable reports
www.8-tree.com
Extremely rich and detailed results – visual and SRM-compliant numeric answers
Handheld Portable design – ideal for the shop floor – no wires, no PC, no power
supply
dentCHECK Dent Reporting Tool (DRT) – “brings the airplane into the office”
All measurement results are digitally captured for ease of record-keeping and
sharing with OEMs and Operators
Zero-learning curve – almost no training required
Compliant with and recognized by OEM standards – Approved by Airbus
Benefits Realized: @ TAP Workflow benefits
www.8-tree.com
dentCHECK reduces Mapping AND Reporting time by >90%
Step Task Time taken (Traditional Methods)
Time taken
( )
1 Setup per dent 5 min 1 min
2 Operator maps a dent on aircraft* 10 min 30 seconds
3 Multiple operators repeat measurements on same dent to verify and reach consensus
10 min 30 seconds
4 Create a dent-mapping report for each dent* 10 min 1 min
Total 35 min 3 min
* In an SRM-compliant fashion
Benefits Realized: @ TAP Time and Efficiency Gains
www.8-tree.com
dentCHECK saves 14 days of time and labor with every day of use
Return on Investment (ROI) period ~2 months
Benchmarking Efficiency & ROI
Man-Hours
Dent Mapping & Reporting
Traditional Methods With
1
2 Dents
30 Dents
8
(1-workday or 1-shift)
16 Dents
240 Dents
www.8-tree.com
“dentCHECK isn’t simply an enhancement to our dent-mapping
processes…
…it’s a huge leap in efficiency!”
Valter Fernandes
EVP, Operations
TAP-Maintenance & Engineering
Empowering Airlines/MROs
www.8-tree.com
• Everything has to support the idea of ease of use
• UX and UI design
• Response time after pushing the button ideally < 1 s
• “Look Ma, no wires!” – No external cables, computers, monitors or
keyboard
• Mobile, handheld, lightweight
• Mechanical Robustness and ‘drop-protected’
• Long-lasting calibration
• All complexity should be hidden inside the box
• Minimal training requirements
www.8-tree.com
Requirements in developing a vision based product for mobile, handheld and shop floor use
Inside the Box:
• A USB3 camera with IMX174 Sensor running at
160 Hz
• A Intel NUC computer with i5 processor
• A Texas Instruments DLP projector
• Powered by 98Wh battery for 4 hours operation
• Scan time 0.1 s
• Evaluation time 2-5 s
• Augmented Reality (AR) projection of results
onto the inspected part
• 2 button operation
www.8-tree.com
How did dentCHECK address these challenges?
Intel NUC computer
DLP projector
IMX 174 Sensor camera
Some of the guidelines below are inspired by early
Apple consumer products. At 8tree, we are convinced
that this design philosophy is very valuable in industrial
products too.
DISCOVERABILITY: The ability to look at the system
and immediately discover all the possible actions
FEEDBACK: Allow a person to know what happened
after an action was taken
RECOVERY: Errors happen. Recovery dictates it should
be as easy or easier to undo than to do
CONSISTENCY: Most technology users have more
than one device, yet the operations of the different
devices often clash
www.8-tree.com
“Don't bend to technology.
Bend technology to your
needs” - Jason Pontin
MIT Technology Review
Design Philosophy in dentCHECK
A key function in dentCHECK is to find out what the undamaged surface would look like
• We call that the Virtual CAD model
• Knowing what is right and what is wrong without further input
• By fitting a mathematical surface to the 3D scan data we can measure and display the size & depth of
a dent
• This works on planar and simple curved surfaces
www.8-tree.com
How does dentCHECK work?
Fitted Surface
8tree products can produce and store meaningful data about their own state…as
well as…
…about the objects being inspected
…provide results through easy to use interfaces for
cloud services or mass storage
…allow insight through big data applications
e.g. predictive maintenance
Industry 4.0 and IoT
www.8-tree.com
Higher image frequency and matching bandwidth on camera-computer interface
Less power consumption from cameras, projectors, computers
Increased processing power
Support of GPU computing
What 8tree would like to see from the vision supply-chain to enable our future roadmap
www.8-tree.com
Ease-of-Use
Intuitive
Portable & Self-
contained
Flexible High-speed
Accurate & Consistent
Zero Learning Curve 1-button operation Tablet/smartphone control No surface preparation needed
Traceable to National Standards
Lightweight No cables or monitor
No external CPU
Actionable Results <2 sec Efficiency boost >10x Real-time feedback
Barcode Configuration
Ease-of-Use that Empowers the Operator
www.8-tree.com
www.8-tree.com
Arun Chhabra
+1 408 813 0969