Basler IP cameras: criteria for German quality.
What do you expect from your surveillance system? Is it supposed to record images 24/7 to reliably protect your property? You may even think that this goes without saying. But often, poor quality surveillance cameras lead to their breakdowns and, as a result, expensive repairs. This should not be! Let's take a look at the quality system criteria used by Basler Vision Technologies, a network camera manufacturer from Ahrensburg, Germany.
The production of IP cameras requires close cooperation between many people and entire departments. Jan Lemke, Head of Production at Basler, explains: “Basler has been continuously investing in our production capabilities in recent years. Through continuous improvement, we have become a leader in quality, cost-effectiveness and flexibility.” At Basler, this is made possible primarily by monitoring the production process and using specially developed control methods.
The cameras are born in the assembly department located at Basler headquarters near Hamburg. The camera boards are filled with electronic components in several assembly manipulators. After soldering the components, all connections in each module and each entire board are checked by an automatic optical inspection system. The functionality of all modules is also checked.
One of the most important stages in camera production takes place in an ISO level 8 cleanroom (up to 100,000 dust particles per foot). This is where the heart of the camera, the image sensor, is installed. The sensor module must be precisely aligned in six degrees of freedom to ensure the optimal distance between the lens base and the sensor. Alignment is performed by an automatic device developed by Basler. This process is extremely important, since even the slightest tilt of the sensor can, for example, result in images that are sharp in the center but blurry at the edges. Due to the high resolution and smaller pixel sizes in many camera models, precise positioning of the image sensor is critical.
Despite the high degree of automation of production, the human factor still remains very important. Firstly, because even the most advanced machines must be operated by qualified personnel. And secondly, some processes in the production of IP cameras are performed manually. This requires optimization of the camera design, and in this context even minor design features become very significant. For example, if only one type of screw is used during assembly, the screws must not be mixed up or installed in the wrong place.
Once the camera has been tested, further calibrations and checks are carried out in the Camera Test Tool (CCT), also developed by Basler. CCT loads the current firmware version into the camera, calibrates the sensor and compares the images captured by the camera with pre-defined samples. All cameras are tested under the same conditions. All camera parameters are checked, including the operation of the IR-cut filter required for day/night modes, Power over Ethernet, and sensor cleanliness. Using these highest quality control standards, Basler can guarantee that each camera delivered to the customer is fully functional and optimally suited for security applications. CCT testing is fully automated and does not require human intervention. All measured camera parameters are statistically analyzed. In the event of, for example, a smooth change in average values, Basler immediately carries out preventive measurements to prevent a possible failure. If a failure is detected, specially trained Basler employees, known within the company as camera doctors, work together with colleagues from production and development to find a solution to the problem.
For new product lines, as well as when an existing line is upgraded, all camera parameters are tested at temperatures from -10°C to +60°C. The back focus length of each Basler IP camera is also measured.
Jan Lemke, Head of Production, explains what is most important in the production process: “The high quality of our cameras depends on a combination of various factors: optimising the camera design for production, careful selection of materials and suppliers, statistical process control and immediate reaction to deviations that occur during production.” Hardy Mehl, Director of IP at Basler, adds: “The advantages in the development and production of our IP cameras are the result of more than 10 years of experience in the industrial camera sector, and we repeatedly optimise all production lines. Another advantage is that we develop all camera elements, hardware and software at our headquarters in Ahrensburg, Germany. This means that we can pool our efforts and capabilities under one roof to ensure that our IP cameras have high image quality and are reliable in operation.”
The manufacturer's responsibility for quality does not end with the sale of the cameras to the customer. If the camera fails, it is important to repair it as quickly as possible. To speed up this process and save time on preparing estimates, Basler takes an unconventional approach: a fixed fee is charged for all post-warranty repairs. Even if the repair is more expensive for the manufacturer than the fixed price, the customer will not pay extra for it.
In addition, Basler uses the RMA process, i.e. each defective camera has a tracking number, the corresponding explanations and batch numbers are recorded in the ERP system. The repair center staff prepares a detailed report, which is important for the continuous improvement of the product characteristics and the production process. This also makes it possible to identify the most common user errors. In this case, the customer receives an immediate answer and, if necessary, additional information is entered into the documentation.
«We see every repair as an opportunity to improve our products and optimize the production process,» says Heinko Schmidt, Head of Customer Service at Basler. «Since introducing feedback from production and development a few years ago, we have been able to significantly reduce the already low failure rate of our cameras.»
Basler AG
An der Strusbek 60-62
D-22926 Ahrensburg
Fon +49 4102 463 0
Fax +49 4102 463 109
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