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Five reasons you need a closed-loop vision system on your converting line
Expert advice from Delta ModTech...
aggressively selling them on a closed- loop vision system. Our sales rep was asked if we sold these systems, to which he replied, “only if you need one.” And therein the conundrum lies. Closed-loop vision systems are an exceptional way to increase your production efficiency. The process, in which sensors or a vision-inspection system make real-time registration corrections, can help in a myriad of ways. However, too many converters buy them because someone sold them on what the system can do, whether it was needed or not. To help you determine if a system is the right fit for you, we review some of the top benefits for a closed-loop vision system.
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WHY YOU NEED A CLOSED-LOOP VISION SYSTEM As a product is converted, the progression, or the repeat, can experience all kinds of issues that can cause variation in the run. Joel Oakes of Delta ModTech pointed out a number of issues that affect registration, including debris on the substrates, static, variable tensions, web thickness (varying material properties), and coefficient friction of rollers. These items have long been the bane of converters and traditionally they have been corrected after the run. The operator will scout out the errors, the machine will be adjusted and the process will begin anew. If the line speed is not too fast, an experienced operator may be able to make adjustments to the machine during the run. We have seen operators manually adjusting the machine via Delta ModTech’s
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customer approached us recently and said a competitor was calling them and
software, for example. These approaches are fraught with inefficiencies, included wasted materials and downtime spent waiting for post-run inspections, and more often than not, human error causes a setback.
THE BENEFITS OF A CLOSED-LOOP VISION SYSTEM Enter the closed-loop vision system, which uses cameras or sensors and servo motor control to make registration an automated process. Everything moves faster as the machine makes the corrections, on the fly. The upside can be enormous, with benefits including the following: 1. Inspection data/traceability reports can
verify quality - Product quality can now be verified by providing a software-generated electronic file, as opposed to the old method of statistical sampling. This is critical when you are required by a regulatory agency to verify your product quality. 2. Real-time feedback - We have mentioned the manual inspection process, which requires verifying the quality at the end of a run or given patch. That methodology increases your scrap rate, and eats up labour costs, especially if a product has to be hand- sorted and discarded in the event of a flaw. 3. Reduces the need for offline inspections - Resources are scarce, and quality control personnel might not be as plentiful as you wish. So your operators may have to wait for a final inspection, especially if a company is busy. That means a strain on the quality control resources, and a waste of time for your operators.
4. Limits the chance of human error - The less variables in a process, the better. If you are relying on the operator to make those
corrections, there is likely going to be inconsistency if you have different quality control personnel across the board. Your operator might just be having a bad day, and suddenly you have a whole batch that needs to be scrapped. 5. Improves staffing resources - Staff are free to focus on other areas of your organisation. This reduces the stress level on your operators, leading to improved working conditions and increased employee retention.
WHEN IS A CLOSED-LOOP VISION SYSTEM NOT SUCH A GOOD IDEA? A closed-loop vision may not be the right fit for you if: 1) You are trying to retrofit an old machine with this new technology. It is an option, but it may actually result in more long-term costs than if you upgraded to a new machine. 2) Your operators are not open to learning something new. You will need to devote training time to make it happen. 3) It is not cost effective. You have to consider the big picture costs before you proceed. No matter what a closed-loop vision system can do, the benefits always need to be balanced with the reality of the situation. Implementing a system will require financial and operational resources, and a commitment from management. In a world of tight tolerances, we all need to also focus on the margins that pay for these machines at the end of the day. Find out how to overcome your biggest converting and packaging challenges. Visit the Delta ModTech Blog and sign up for our newsletter on the website below.
www.deltamodtech.com/blog www.convertermag.co.uk
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