The document describes Project Checkmate 65, which involves developing a fully automatic print inspection machine. A prototype has been completed and demonstrated successfully to customers. The machine aims to automate and improve consistency of inspecting printed cartons at high speeds. It is budgeted at 30 lakhs and involves innovative applications of technology like high-speed cameras. The project promotes self-reliance in India and is expected to positively impact print quality and reduce costs for printers.

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.