Enhancing Quality Control in Battery Component Manufacturing: Deep Learning-Based Approaches for Defect Detection on Microfasteners

Abstract

The management of product quality is a crucial process in factory manufacturing. However, this approach still has some limitations, e.g., depending on the expertise of the engineer in evaluating products and being time consuming. Various approaches using deep learning in automatic defect detection and classification during production have been introduced to overcome these limitations. In this paper, we study applying different deep learning approaches and computer vision methods to detect scratches on the surface of microfasteners used in rechargeable batteries. Furthermore, we introduce an architecture with statistical quality control (SQC) to continuously improve the efficiency and accuracy of the product quality. The proposed architecture takes advantage of the capability of deep learning approaches, computer vision techniques, and SQC to automate the defect detection process and quality improvement. The proposed approach was evaluated using a real dataset comprising 1150 microfastener surface images obtained from a factory in Korea. In the study, we compared the direct and indirect prediction methods for predicting the scratches on the surface of the microfasteners and achieved the best accuracy of 0.91 with the indirect prediction approach. Notably, the indirect prediction method was more efficient than the traditional one. Furthermore, using control charts in SQC to analyze predicted defects in the production process helped operators understand the efficiency of the production line and make appropriate decisions in the manufacturing process, hence improving product quality management.