INSPECTOR 4.0 is a control unit for manufacturing enviroment, comprising an industrial PC with a color touch screen interface (10,4” LCD screen), SSD and Windows embedded operating system
Thanks to the numerous applications available, INSPECTOR can:
– manage one or more print devices, directly from the production line and in total security. It includes functions such as preview, manage layout variables, automatic selection of last printed label on each restart (Print Only)
– automatically update graphics to be printed based on one (Change) or more (Label
Management Slim) identification elements detected from the field
– trace production, recording unambiguous identifiers on packages, for each production lot, with the possibility of reconciling rejects (Tracking Slim and Tracking Slim Pharma).
– control code readers and vision sensors for “packaging validation” (Code Check function) and monitor the degree of readability, maintaining production continuity (Code Verification)
PRINT MANAGEMENT & VALIDATION
– detect all production data: products processed, discarded, line downtimes, etc. (Production Monitor)
– quickly start up the line, via “product work
programs”, memorizing and recalling configuration parameters for Arca devices (Quick Set Up)
– profile operators with differentiated security levels and management of access (User Security), including biometric recognition
– check all application functions for any Arca print apply unit or labeler connected (any model equipped with Advanced electronics), via an additional, simple and intuitive graphic interface
Competitive markets impose increasingly greater productivity.
The growing variety of products (formats, versions, fragrances, flavors, etc) increases the number of packagings managed. Ongoing changes to graphics, linked to promotions and constantly evolving legislation, further complicate matters on the packaging line.
In such a complex scenario, production is subject to a multitude of risks
– Unreadable barcodes/2D codes
Large-scale retailing demands codes that can easily be read using normal laser scanners. Unreadable codes can cost suppliers, with the pallet even being returned
– Mix ups of unit packages
Putting a batch or even just a single product with the wrong packaging onto the market can have serious consequences, especially in the pharmaceutical and food sectors.
Recalling a batch for repackaging is extremely costly and is often impossible for perishable food products. The damage to corporate image can be considerable
– Logistical mix ups
Each unit package must be vehicled in the correct multiple package: bundle, box or pallet
The Code Verification software, installed on an Inspector control unit, is the most advanced solution for managing barcode and 2D code scanners:
1) code readability check (good read / no good read)
2) conformity check of the code read to the specific code set at the start of production, with correspondence to a specific value
3) analysis of the grade of readability (as per the ANSI grade) expressed as a percentage, with an advance alarm in the case of a decline in print quality below a preset minimum threshold
The advance alarm is aimed at notifying and assisting the operator in label reel changes (no additional line stoppages) and operating head and/or scanner cleaning before unreadable codes get printed
4) check of conformity of the code read to a family of preset codes (useful in the case of constantly variable code)
5) management of a possible product ejector, (still or moving)
6) display of hardware alarm conditions: pneumatic ejector not working, product not ejected, scanner (or ejector) activation photocell malfunctioning or not working
7) possibility of setting up to 5 conventional print quality ranges, based on the percentage of readability provided by the barcode scanner
8) possibility of setting the activation of alarms and advance alarms, in relation to preset limits exceeded by “n” times (consecutive or otherwise) For example: alarm at 1st wrong code, advance alarm after 3 codes whose print quality is less than 50%, etc.
9) real time graphic display, with alternative modes, of the impact of defects and the degree of readability of each code, in the medium term for the production lot
10) graphic representation of the barcode’s actual positioning on the product with respect to an ideal point
11) management of alarms, reprinting and reapplication of labels with incorrect codes (requires labeling on still products). After “n” incorrect reprints, possibility of managing the line stoppage or label application indicating the “non-conformity”
12) management of the barcode scanner’s
13) recording of readings and important production data with possibility of its export
The Code Verification software is embedded in the “Validation and print management” interface for Inspector 4.0 control unit