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