Date post: | 18-Jan-2015 |
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CHECKMATE 65 PRINT INSPECTION
MACHINE
PROJECT TITLE
A FULLY AUTOMATIC PRINT INSPECTION
MACHINE INSPECTING CARTONS USED
FOR PACKAGING AT VERY HIGH SPEED
PROJECT DESCRIPTION
PHOTOGRAPH
VIDEO
PROJECT DETAILS
PROTOTYPE COMPLETED AND
LAUNCHED.
CONDUCTED 4 SUCESSFUL DETAILED
CUSTOMER DEMONSTRATIONS.
WILL BE SOLD TO A BETA SITE DURING
OCTOBER 2013
PROJECT STATUS
2013-2014
YEAR OF INCEPTION
30 LAKHS
BUDGETED COST
SO FAR PRINTED CARTONS ARE INSPECTED
ONLY MANUALLY.
QUALITY OF PRINTED CARTONS ARE VERY
INCONSISTENT RESULTING IN HUGE REJECTIONS.
CONSISTENCY AND PRODUCTIVITY VARIES FROM
PERSON TO PERSON.
PRODUCT SUTABLITY FOR THIS AWARD
THIS MACHINE AUTOMATES ABOVE PROCESS
FOR 100%INSPECTION AND ENSURES COMPLETE
QUALITY.
SEGREGATES THE GOOD AND BAD CARTONS
SEPERATELY TO PREVENT MIX UP.
PRODUCT SUTABLITY FOR THIS AWARD
► FIRST OF ITS KIND IN INDIA TO INTEGRATE CAMERA FOR
PRINT INSPECTION.
► A COST EFFECTIVE SOLUTION TO AUTOMATE THE
PROCESS WHICH HAS, A LESS THAN 3 YEAR PAYBACK,
ON ONLY LABOUR COST SAVING.
► MACHINE CAN CHECK WITH VARIABLE TOLERANCES AT
DIFFERENT POINTS ON THE CARTONS TO REPLICATE A
MANUAL PROCESS.
► WITHIN 50 MILLI SECONDS A PRINT IS SCANNED WITH
TWO CAMERAS, BOTH THE IMAGES VERIFIED WITH A
MASTER IMAGE AND SEGREGATED AND NEATLY
STACKED.
PROJECT INNOVATIVENESS
► MACHINE HIGHLIGHTS THE DEFECTS& GIVES REPORTS
FOR FURTHER CORRECTIVE ACTION
► IMAGES ARE CHECKED AT A RESOLUTION OF 0.1mm X 0.1mm,AT A SPEED OF 150m/min,GIVING A PRODUCTION OF AROUND 50000 CARTONS INSPECTED AND SEGREGATED PER HOUR.
► MACHINE USES HIGH SPEED PNEUMATIC SYSTEMS TO
REACT AT LESS THAN 50 milli seconds.FOR SEGGERGATION.
► MACHINE USES MOST OF THE HIGH END TECHNOLOGIES
LIKE ,SERVO MOTORS,HMI,HIGH SPEED CAMERAS,HIGH
END SOFTWARE ETC.
PROJECT INNOVATIVESS
A MARKET SURVEY WAS DONE ON THE REQUIREMENT
FOR THIS PRODUCT.
MANY POSSIBLE ALTERNATIVES WERE EVALUATED
RIGHT AT THE BEGINNING OF THE PROJECT(BRAIN
STORMING,EXHIBITION VISITS,CUSTOMER MEETS ETC)
CLEAR PLAN FROZEN AND THEN DESIGNING WAS
STARTED.
BEST PRACTICES LIKE,MODEL CREATION,FINITE
ELEMENT ANALYSIS,GEOMETRIC DIMENSIONING AND
TOLERANCING ANALYSIS,ASSEMBLY CREATION,VIRTUAL
SIMULATION (CRITICAL AREA)WERE DONE BEFORE THE
ACTUAL PROTOTYPE WAS EXECUTED
OPERATIONAL EXCELLENCE
AESTIETICS AND ERGONOMICS WERE ANALYSED FOR
EASY OPERATION AND LESS STRAIN FOR THE
OPERATERS.
VALIDATION ON THE PROTYPE RUNNING WAS DONE
LIKE, LONG TIME NON STOP RUNNING LIKE 48 HOURS,
TEMPERATURE RISE TEST AT DIFFERENT POINTS, NOISE
LEVEL TEST, VIBRATION TEST, REPEATIBILITY TEST FOR
INSPECTION QUALITY UPTO 25 TIMES OF REPEAT
INSPECTION.
A SET OF PRODUCTIONISING DOCUMENTS (26 NOS) IS
BEING RELEASED FOR EASY PRODUCTION AND
MAINTAINENCE OF THE PRODUCT
OPERATIONAL EXCELLENCE
AUTOPRINT IS THE ONLY MANUFACTURER IN INDIA TO
MAKE THIS PRODUCT.
SAVES VALUABLE FOREIGN EXCHANGE FOR THE
COUNTRY (IMPORTED MACHINE COSTS 1.3 CRORES
WHERE AS CHECKMATE COSTS 45 LAKHS WITHOUT ANY
COMPROMISE IN QUALITY)
HAS A GOOD EXPORT MARKET AND HENCE WILL
IMPROVE THE BALANCE OF PAYMENT FOR THE
COUNTRY.
SELF RELIANCE IN INDIA
EXPORT OF PRINT PRODUCTS WILL INCREASE DUE TO
BETTER QUALITY .
IMPORT CONTENT ON THE MACHINE IS VERY LOW.
SELF RELIANCE IN INDIA
100% ASSURED AUTOMATIC QUALITY INSPECTION ,HAS
BECOME MORE AFFORDABLE FOR PRINTERS.
PRINT QUALITY ASSURANCE WILL EXPAND THE MARKET
FOR THE PRINTERS AND HELP IN EXPORTING TO
DEVELOPED COUNTRIES WITH CONFIDENCE.
MENTAL STRESS ON THE QUALITY INSPECTORS WILL BE
REDUCED AS THIS IS A RISKY CRITICAL JOB.
KEY IMPACT
PROCESS REJECTIONS WILL REDUCE AND PRINTERS
WILL BECOME MORE COST EFFECTIVE.
PRINTING COMPANIES’S CULTURE CHANGES TOWARDS
BETTER QUALITY
KEY IMPACT
100%PRINT INSPECTION IS JUST IN THE INFANCY STAGE
AND HAS A GREAT FUTURE ALL OVER THE WORLD.
QUALITY CONCIOUSNESS HAS BECOME A NORM AND
CURRENCY,PHARMA ,FMCG,CIGRETTES ARE DRIVING
THIS CHANGE AS THE PENALTY FOR THEM IS VERY
HUGE.
GREY MARKET IS A HUGE PROBLEM AND END USERS
ARE INTRODUCING MANY SECURITY FEATURES FOR THE
PRODUCTS WHICH HAS TO BE INSPECTED.(EG;2D BAR
CODES,HOLOGRAM,INVISIBLE INKS ETC).
FUTURE READINESS
PRODUCT HAS BEEN MADE WORLD CLASS LIKE CE
ENABLED
PRODUCT HAS BEEN MADE WITH A PROVISION FOR
REMOTE ACCESS AND SERVICE SUPPORT WORLD WIDE
CAN BE GIVEN THROUGH REMOTE COMPUTER.
FUTURE READINESS