Amer Imtiaz Ali

Manufacturing Project Engineering, driving new-product launches, automation implementation and continuous improvement in high-volume manufacturing environment. Expert in leveraging SAP/ERP systems, GD&T, tooling/fixture design and robotics-vision integration to reduce cycle times, scrap and downtime while ensuring compliance to customer specifications. Adept at collaborating across operations, maintenance, quality and logistics teams, and mobilizing global resources for best-in-class manufacturing solutions.

Enhancing Automation in Manufacturing!

I’m thrilled to share my key projects I contributed to recently. These projects highlights the integration of robotics into industrial operations for precision and efficiency.

1. 3D Vision Automated Bin Picking Application Set-up includes:

• Collaborative Robot (Cobot): Ensures seamless pick-and-place operations.
• 3D Vision System: Detects parts and ensures they are oriented correctly for the next process.
• Magnetic Gripper: Enhanced with custom-designed, in-house 3D-printed components to securely and precisely handle parts.
• Pneumatic Loading Mechanism: Smoothly loads parts into the machine for the next step in the process.
• Custom Safety Guarding: Designed in-house to ensure safe operation at high speeds, enabling the system to achieve a blazing-fast cycle time of just 6 seconds!
• Rigid Base Frame: Provides a stable platform for the robot, ensuring no movement during pick-and-place operations, even at high speeds.

This solution streamlines the workflow, enhances productivity, and demonstrates how robotics, vision systems, and custom engineering can tackle complex manufacturing challenges.

This system:

• Optimizes workflow and reduces manual effort.
• Demonstrates how technology streamlines processes in manufacturing environments.

It’s inspiring to see how advancements in automation are reshaping industries. I’m looking forward to exploring more opportunities in industrial security and automation.

This project has been an exciting blend of problem-solving, collaboration, and innovation!

2. AI-Based vision inspection cell for high-volume production part
Developed and implemented an advanced AI vision inspection cell for high-volume production parts. The system integrates a Fanuc CRX-series collaborative robot (cobot) equipped with a safety scanner for operator protection, and an AI vision module utilizing a GigE cameras with proprietary AI-based defect detection software. Parts are presented to the robot through a retooled in-house gantry system, repurposed from an older vision cell to reduce capital costs. The retrofit included replacement of all servo motors and PLCs with upgraded control hardware, providing smoother motion and higher reliability.

The inspection process occurs inside a light-controlled illuminated cube to ensure consistent lighting and image quality. The system performs automated detection of dimensional and surface defects — including overall length, hole presence (verified via pixel-count and histogram-based rule logic), nicks, dings, scratches, raised material, and chip-off grooves. Integrated reject trays automatically segregate non-conforming parts.

This implementation cut inspection cycle time from 20 seconds @ 80 % efficiency to 10 seconds @ 95 % efficiency, replaced three to four manual inspectors per shift, and achieved an ROI of less than one year, while significantly improving traceability, process consistency, and system reliability.