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Autoprint machinery mfg. pvt. ltd

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Autoprint machinery mfg. pvt. ltd

Autoprint machinery mfg. pvt. ltd

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  • 1. PROJECT TITLE CHECKMATE 65 PRINT INSPECTION MACHINE
  • 2. PROJECT DESCRIPTION  A FULLY AUTOMATIC PRINT INSPECTION MACHINE INSPECTING CARTONS USED FOR PACKAGING AT VERY HIGH SPEED
  • 3. PROJECT DETAILS  PHOTOGRAPH  VIDEO
  • 4. PROJECT STATUS  PROTOTYPE COMPLETED AND LAUNCHED.  CONDUCTED 4 SUCESSFUL DETAILED CUSTOMER DEMONSTRATIONS.  WILL BE SOLD TO A BETA SITE DURING OCTOBER 2013
  • 5. YEAR OF INCEPTION 2013-2014
  • 6. BUDGETED COST 30 LAKHS
  • 7. PRODUCT SUTABLITY FOR THIS AWARD  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.
  • 8. 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.
  • 9. PROJECT INNOVATIVENESS ► 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.
  • 10. PROJECT INNOVATIVESS ► 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.
  • 11. OPERATIONAL EXCELLENCE 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
  • 12. 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
  • 13. SELF RELIANCE IN INDIA 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.
  • 14. SELF RELIANCE IN INDIA EXPORT OF PRINT PRODUCTS WILL INCREASE DUE TO BETTER QUALITY .  IMPORT CONTENT ON THE MACHINE IS VERY LOW.
  • 15. KEY IMPACT  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.
  • 16. KEY IMPACT  PROCESS REJECTIONS WILL REDUCE AND PRINTERS WILL BECOME MORE COST EFFECTIVE.  PRINTING COMPANIES’S CULTURE CHANGES TOWARDS BETTER QUALITY
  • 17. FUTURE READINESS 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).
  • 18. 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.