Ensure barcode and printed text quality with machine vision verification 1
Presented by Jonathan Ludlow Machine Vision Promoter at Microscan Sadie Zeller Product Manager at Microscan 2
About Microscan Founded in 1982, technology innovator and leader for 30+ years Inventor of laser diode scanners and Data Matrix symbology Focused on Track, Trace & Control solutions Capabilities from barcode reading to precise vision inspection A Spectris company 3
Agenda 1. Effects of barcode quality and legibility on product traceability 2. In-line machine vision verification 3. Ensuring product quality and safety with OCR/OCV and inspection 4. Case study machine vision and traceability in food manufacturing 5. Q&A 4
The Problem with Unreadable Codes and Text 5
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Definitions and Symbology Basics Many Machine Readable Codes for AutoID 1D Bar Codes 2D Symbologies 2D Bar Codes QR Code 7
Data Matrix Code A Brief Tutorial Microscan invented the Data Matrix code and placed it in the public domain Data Matrix advantages: Small size - Highest information density Digital encoding Readable in any orientation, scalable Built-in error correction Low contrast requirement 8
Why Do Good Codes Go Bad? Every Marking System Degrades Over Time Barcodes NEVER Get Better After Leaving the Marking System Human Error Can Result in Product and Packaging Mix-Ups 9
Pain Points and Problems Process Downtime Waste/Scrap Unreadable codes due to poor print quality or damage Loss of Identity or Traceability Upset or Confused Customers Incorrect code or text format/content Regulatory Issues 10
Various Marking Applications Print serialized barcodes on labels or product packaging Print product codes on secondary packaging Directly mark parts with identifying code 11
Example: Direct Print on Cardboard Cartons Direct printing is economical Symbol quality varies greatly Large retailers fine vendors for no reads 12
Example: Printed Labels on Pharmaceuticals 1D and 2D Verification High Mark Contrast Substrate is Controlled Stringent Traceability Requirements Regulations Requiring Verification of Date and Lot Codes (FDA) 13
Poll 1 What are the biggest issues your company is facing due to poor barcode or text quality? Quality control issues Waste/scrap Process downtime Customer fines or returned material None of the above 14
Machine Vision Verification 15
Reading vs. Verification Reading tells you only that the code can be read right now by your barcode reader. It may still be unreadable by your customer s reader. Verification tells you not only that you can read a mark, but also how close you are to the edge of readability or if you are heading that way. It ensures that any suitable reader can read. 16
Common Methods of Inspection Off line verification Problem in marking method undetected until next sample Scrap and downtime to determine scope of issue Scanner/Imager to confirm code can be read Does not tell how well it can be read Does not analyze the code and provide data Does not allow for trending based triggers Does not alert to a problem until there actually is one. 17
What Is Machine Vision Verification? Measuring the quality of a barcode to a published standard Verification results are expressed in grades 4 / A = perfect 0 / F = very poor or unreadable Standards: ISO 15415 Printed 2D Codes ISO 15416 Printed 1D Codes AIM DPM-1-2006/ISO 29158 Direct Part Marks Machine vision verification is camera-based 18
Find out if the marking system is degrading before you have a problem Without verification, thousands of bad parts escape into the process With verification, we prevent bad barcodes from ever being made 19
Two Levels of Quality Grading Process Control/ Validation: validate the quality of the applied code/mark to internal quality standards Conformance Verification: verify that the applied code/mark meets ISO or AIM standards 20
In-line verification ensures that EVERY product ships with a good quality barcode 21
In-Line Verification 22 Grading (0.0 to 4.0) each code at the point of marking Instant feedback on code grade/quality Instant warning of low grade/unreadable codes Able to observe trends Optional logging of grade results and images
Action Based on Data Purge Event Define purge trigger/alarm point Printer purge cleans ink jet head 23
Before and After a Printer Purge Before After 24
Recommended Verification Platforms True verification requires ISO/AIM-compliant light & undistorted image C-Mount lenses preferred Perpendicular mounting to avoid perspective distortion* Shield from ambient light Fixed distance At least 8 pixels per element* A short (<250µs) exposure time for moving symbols * Per the applicable standard 25
Configuration Examples Complete verification kits based on application needs Include smart camera, lens, lighting and mounts Barcode Verification Monitoring Interface (VMI) Large Linear 1D codes 1D/2D Glossy Labels Dot Peen DPM 2D codes 26
Poll 2 Which methods do you use to check barcode quality? 1. Visual inspection 2. Confirm codes can be read with a barcode reader 3. Offline verification of samples to internal quality standards 4. Offline verification of samples to ISO or AIM standards 5. 100% verification to internal quality standards 6. 100% verification to ISO or AIM standards 7. None 27
Ensuring Quality and Safety with AutoID and Machine Vision 28
What is AutoVISION? Microscan s AutoVISION family includes a flexible line of smart cameras that run the intuitive AutoVISION software, enabling easy implementation of machine vision inspection by users of all skill levels. Machine Vision, Simplified. 29
AutoVISION TM Machine Vision Solutions for off-line and in-line grading Verification is a tool in AutoVISION 30
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How can you ensure quality and safety? Auto ID Tracking & Traceability Match inserts to packaging Barcode and 2D any marking method Item traceability Anti-counterfeiting measures Visual Inspection Date and lot verification Safety seal inspection Label presence/position Package integrity 33 Precision Measurement Fill levels Cap/seal/label alignment Quality assurance
Optical Character Reading (OCR) Optical Character Verification (OCV) Terms often used incorrectly NOT the same OCR: Optical Character Recognition OCV: Optical Character Verification OCR is an automatic identification tool Typically looks at variable text Gives a best estimate of text content, not good at assessing print quality OCR is intended to read poor quality characters OCV a print quality inspection tool Typically used on fixed text Checks for correctness, quality, contrast and sharpness OCV is intended to flag & reject poor quality characters 34
AutoID+ in Action OCR copes with variation in text OCV detects variation in text 35
Application Example: Label Content Validation 1D or 2D Match Strings Static or Dynamic Match GS1 Application Identifier (AI ) Fields with Human Readable text Human Readable Match Strings Static or Dynamic External Match String Assignment (Serial, TCP, EIP, or Profinet) 36
Application Example: Error Prevention in Food Packaging Problem: Cups and lids don t match Incorrect packaging for product Solution: Match Data Matrix code or OCR on the lid to a barcode on the cup to ensure correctness Line stops on errors Result: 37 System ensures immediate results & avoids human error ROI - under 3 months
Application Example: High Speed Can InkJet Code Read Data Matrix reading OCR (rotated ROI) 400-500 PPM 38
Application Example: Bright Stock Print Legibility Variety code print legibility Over 1000 PPM Visionscape GigE camera and NERLITE CDI light 39
Application Example: Print Presence Print Present No Print 40
Poll 3 How do you currently inspect printed text on your product? 1. Visual inspection on samples pulled from production 2. Visual inspection on samples pulled from finished goods 3. 100% visual inspection 4. Vision sensors 5. Machine vision 6. We do not inspect printed text 41
Case Study: Machine vision technology ensures product quality and traceability at food manufacturer 42
Case: Food manufacturing Solution Requirements: Improved quality and accuracy of the printed product code on every can Assurance that every can receives the correct label Improved overall traceability of canned fruits and vegetables 43
Case: Food manufacturing How it works: Machine Vision system with cameras at multiple key points, supported by Microscan s advanced Visionscape software. Inspection and verification of printed product codes, UPC/2D codes on product labels, and finished cases at varying operating speeds up to 1,200 cans per minute. Any code that is missing or unreadable is rejected. If the system detects the wrong code, the line will shut down and alert the operator. 44
Case: Food manufacturing How it works: PLC control Data to a SQL database Custom user screens for monitoring and easy changeovers Monitoring of pass/fail counts, current and last failed images, Setting inspection tolerances and imaging parameters Remote support capability. 45
Case: Food manufacturing Solution Benefits: Accurate labeling assures the reseller and end-user of the product that there will be no surprises when opening the can. Inspection is critical for compliance with allergen labeling and prevents product recalls due to mislabeling. Expanded traceability limits the extent of a recall should one become necessary, and speeds troubleshooting by helping to identify precisely where an error has occurred. 46
Thank you! Q&A For more information: www.microscan.com info@microscan.com 47