Packaging
EXECUTIVE SUMMARY
World Leading process management company had a peculiar situation wherein there were reported errors in packaging and the identified issues pointed towards manual errors due to operators. This led to ‘loss of revenue’, ‘additional cost overheads’ and was affecting the ‘brand image’ adversely.
There was an urgent need to devise a system that identified packaging errors so that solutions could be implemented at run time.
CHALLENGE ASSESSMENT
Understanding the nature of operations and the sequencing of packaging and dispatch was crucial to assess the points for inspection and propose potential solutions.
The team consolidated a strategy, identifying the optimal camera and lenses along with lighting systems. There were multiple types of sensor units and the assembly was to pack different size of boxes with multiple layers. This change in perspective and variance posed some challenges that could affect the image quality and focus.
1. Manual ( operator ) error and intervention reduction
2. Few assembly components are similar in shape and size. Difficult to identify. Need complex algorithm.
3. Environmental impact and ‘Cost to build’ feasibility study
IMPACT STATEMENT
Ceryletech is glad to have implemented a solution that dovetails into the assembly line seamlessly with virtually no down time on the line. Implementing this vision system, has resulted in 100% accuracy in packaging system. Production data also can be stored and traces back to inventory for a more analytical solution that is ‘Business ready’, poised and compact in turns of scalability and report generation.
Solution
Camera based vision solution proposed to client. National Instruments Vision controller was deployed, with ‘learning’ facility incorporated, permitting operators to train the system to adjust or add new models. Software’s outputs was integrated to their global software for further traceability and business integration
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