Mittelstandspresse
31.07.2026
How EMG iCAM® Improves Yield, Quality and Productivity
From Measurement to Process Optimisation
Wenden, 31.07.2026 (PresseBox) - In the first two articles of this series, we examined why conventional strip width measurement systems are increasingly reaching their limits and how the optical multi-camera technology of EMG iCAM® addresses the requirements of modern flat metal production.
However, measurement accuracy and technological performance are not ends in themselves. The decisive question for producers is how reliable inline measurement contributes to better material utilisation, more stable production processes and consistently high product quality.
This is where EMG iCAM® goes beyond the role of a conventional width measurement system. By providing continuous and transparent information about strip dimensions and, depending on the selected system configuration, individual slit strip widths or holes, the system creates a reliable data basis for process control, quality assurance and further optimisation.
Improving Material Yield Through Precise Width Measurement
Material yield is one of the most important economic factors in flat metal production. Even small amounts of unnecessary edge trim can accumulate into substantial material losses when calculated across large production volumes.
Inaccurate or unstable strip width information often leads producers to work with additional safety margins during trimming. More material is removed than technically necessary to ensure that the finished strip remains within the required tolerance. Although this approach reduces the risk of undersized material, it also lowers yield and increases production costs.
Continuous and precise strip width measurement allows trimming processes to operate with narrower safety margins. EMG iCAM® provides reliable width information over the entire coil length, helping operators to identify dimensional changes and optimise the trimming process accordingly.
The result is more efficient use of the processed material, less unnecessary edge trim and a direct contribution to reducing the cost per tonne of saleable product. This benefit becomes particularly relevant when processing high-value steel or aluminium grades, where even small improvements in yield can have a significant economic impact.
Supporting Stable Slitting Processes
In slitting applications, the quality of the finished product depends not only on the overall width of the incoming strip but also on the dimensions of each individual slit strip.
The relevant EMG iCAM® configuration combines strip width measurement with slit strip width measurement. It continuously monitors the individual strips and provides precise dimensional data over the full coil length. With measurement accuracies of up to ±0.1 mm for strip width and up to ±0.05 mm for slit strip width, the system supports accurate knife positioning and reliable verification of the slitting result.
This information can be used during line start-up to check and adjust the knife positions. During continuous operation, deviations can be identified at an early stage before they affect larger quantities of material.
Transparent measurement data also makes it easier to distinguish between isolated dimensional variations and systematic process deviations. Operators and quality departments can respond more quickly, reduce rework and prevent non-conforming material from progressing further through the production chain.
Preventing the Processing of Defective Material
For applications in which material integrity is critical, EMG iCAM® can alternatively combine strip width measurement with inline hole detection.
Holes in the strip can cause serious problems in downstream coating, forming, stamping or pressing processes. If defective material is not detected early, it may continue through several value-adding production steps before the problem becomes visible.This consumes production capacity, energy and operating time while creating scrap that could have been avoided.
EMG iCAM® detects and localises holes across the strip width and length in real time. Depending on line speed, material thickness and application conditions, holes down to approximately 0.2 × 0.2 mm can be detected.
The measurement information enables affected material sections to be identified before they enter sensitive downstream operations. Producers can therefore classify material more reliably, separate unsuitable sections and avoid processing material that cannot meet the required quality specification.
The benefit is not limited to lower scrap rates. Early detection also reduces the risk of production interruptions, damage to downstream equipment and rejected finished products.
Turning Continuous Measurement Data into Process Transparency
A single width value provides only limited information about the performance of a production process. Continuous inline measurement, by contrast, creates a profile over the complete coil length and makes gradual changes, local deviations and recurring patterns visible.
EMG iCAM® combines real-time inline measurement with online visualisation, statistical evaluation and offline analysis. Operators can monitor current values during production, while quality departments can review the results for individual coils and document compliance with dimensional requirements.
The measurement and quality data can also be transferred to higher-level automation and quality management systems through standard industrial interfaces such as ProfiNET or TCP/IP. This avoids isolated data structures and makes the information available wherever it is needed for production control, quality documentation or further analysis.
Greater transparency shortens the time between the occurrence of a deviation and the corresponding corrective action. Instead of relying primarily on downstream inspection or individual samples, producers gain continuous information directly from the running process.
Reliable Measurement as a Basis for Lower Operating Costs
The economic value of a measurement system is influenced not only by its accuracy but also by its reliability and maintenance requirements.
The non-contact measuring principle of EMG iCAM® avoids mechanical interaction with the strip. Since the system contains no mechanically moving measuring components, there is no associated wear, mechanical tracking or regular repositioning of sensor heads.
The infrared backlight and multi-camera arrangement are designed for stable continuous operation. Combined with fast FPGA-based data processing, the system supports high line speeds while maintaining consistent measurement performance.
Low maintenance requirements, reduced wear and high system availability contribute to a lower total cost of ownership. At the same time, the modular system design allows the configuration to be adapted to the actual application instead of installing unnecessary hardware.
The possibility of adding slit strip width measurement or hole detection also to an existing EMG iCAM® width measurement system by means of a software upgrade also protects the initial investment. The platform can evolve with changing production requirements without requiring a completely new measurement system.
Preparing for Smart Manufacturing
The increasing digitalisation of flat metal production is changing the role of measurement systems. Sensors and quality assurance systems are no longer isolated devices. They are becoming important data sources within connected production environments.
EMG iCAM® supplies continuous and clearly assignable information about strip dimensions and material quality. Combined with coil, material and process data, this information can support more advanced analyses and help identify relationships that are difficult to detect through individual measurements alone.
The data can also be integrated into platforms such as EMG iCASS®. In this context, EMG iCAM® remains the precise inline data source, while EMG iCASS® can combine its results with further process and quality information for statistical analysis, machine-learning applications and process optimisation.
This opens up possibilities that extend beyond the immediate monitoring of tolerances. For example, producers can investigate which process conditions contribute to dimensional deviations, detect changes in process behaviour earlier or develop data-based approaches for optimising trimming and slitting operations.
EMG iCAM® represents in this sense one possible next step in the development from transparent measurement data towards connected and intelligent production processes.
From Quality Control to Measurable Process Value
Modern width measurement must do more than confirm whether a strip is within tolerance. It should help producers use material more efficiently, stabilise downstream processes, detect defective sections early and create a transparent basis for continuous improvement.
EMG iCAM® supports these objectives by combining precise, continuous strip width measurement either with slit strip width measurement or with inline hole detection. The system transforms measurement results into actionable process and quality information.
Its contribution can be seen in reduced edge trim, improved material yield, more stable slitting processes, fewer quality-related interruptions and better integration of production data.
In this way, EMG iCAM® develops from a measuring system into an important component of modern quality assurance and process optimisation — providing immediate operational benefits while creating a foundation for future smart-manufacturing applications.
More Information
For further information about EMG iCAM® and its applications in modern flat metal production, please contact our product management team at icam@emg-automation.com or our international sales and service organisation.
Previous articles in this series:
Modern Strip Production Requires More Than Conventional Width Measurement
Inside EMG iCAM®: The Technology Behind High-Precision Strip Width Measurement
Download:
Product brochure: Inline measurement of strip & slit strip width & hole detection with EMG iCAM®
Ansprechpartner
Claudia Schreiner
+49 (2762) 612-282
Zuständigkeitsbereich: Product Marketing EMG Automation GmbH
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How EMG iCAM® Improves Yield, Quality and Productivity
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