ensure barcode and printed text quality with...
TRANSCRIPT
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© Microscan Systems Inc. © Microscan Systems Inc. 1
Ensure barcode and
printed text quality with
machine vision verification
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© Microscan Systems Inc. © Microscan Systems Inc. 2
Presented by
Jonathan Ludlow
Machine Vision Promoter at Microscan
Sadie Zeller
Product Manager at Microscan
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© Microscan Systems Inc. © Microscan Systems Inc. 3
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
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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
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The Problem with
Unreadable Codes and Text
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Many Machine Readable Codes for AutoID
1D Bar Codes
2D Symbologies – “2D Bar Codes”
Definitions and Symbology Basics
QR Code
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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
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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
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Incorrect code or
text format/content
Regulatory
Issues
Loss of Identity
or Traceability
Pain Points and
Problems
Upset or
Confused
Customers
Unreadable codes due
to poor print quality or
damage
Process Downtime
Waste/Scrap
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Various Marking Applications
Print serialized barcodes on labels or product
packaging
Print product codes on secondary packaging
Directly mark parts with identifying code
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Example:
Direct Print on Cardboard Cartons
Direct printing is
economical
Symbol quality varies
greatly
Large retailers fine
vendors for no reads
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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)
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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
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Machine Vision Verification
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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.
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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.
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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
What Is Machine Vision
Verification?
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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
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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
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In-line verification
ensures that EVERY
product ships with a
good quality barcode
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In-Line
Verification
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
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Action Based on Data – Purge Event
Define purge trigger/alarm point
Printer purge cleans ink jet head
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Before and After a Printer Purge
Before
After
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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
Recommended Verification Platforms
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Complete verification kits based on application needs
Include smart camera, lens, lighting and mounts
Barcode Verification Monitoring Interface (VMI)
Dot Peen DPM 2D codes 1D/2D Glossy Labels Large Linear 1D codes
Configuration Examples
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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
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Ensuring Quality and Safety with
AutoID and Machine Vision
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What is AutoVISION?
Machine Vision, Simplified.
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.
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AutoVISIONTM Machine Vision Solutions
for off-line and in-line grading
Verification is a
tool in
AutoVISION
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How can you ensure quality and safety?
33
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
Precision Measurement
Fill levels
Cap/seal/label alignment
Quality assurance
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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
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OCR copes with
variation in text
OCV detects
variation in text
AutoID+ in Action
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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)
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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:
System ensures immediate
results & avoids human error
ROI - under 3 months
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Application Example:
High Speed Can InkJet Code Read
Data Matrix reading
OCR (rotated ROI)
400-500 PPM
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Application Example:
Bright Stock Print Legibility
Variety code print
legibility
Over 1000 PPM
Visionscape GigE
camera and NERLITE
CDI light
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Application Example:
Print Presence
Print Present
No Print
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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
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Case Study:
Machine vision technology ensures
product quality and traceability at
food manufacturer
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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
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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.
Case: Food manufacturing
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.
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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.
Case: Food manufacturing
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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.
Case: Food manufacturing
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