While manual inspections involve physical reviews of products and quality of workmanship, vision inspection systems use advanced cameras and image processing technology for parallel inspections. Shubham Automation’s developed automated vision inspection solution called PCC ACCURA plays a vital role in achieving comprehensive quality assurance and manufacturing control in diverse industries. This scenario further helps in reducing the overall manufacturing costs and ensuring a superior level of customer contentment.
Conventional vision inspections lead to lower speed processes, errors, and dependency on human resources. On the other hand, manufacturers are using automated vision inspection solutions in high-speed processes, higher magnification, 24/7 operations, and repeatability of tasks. A step further, automated technology offers machines and devices the capability to inspect scenarios or objects to make precise quality assurance decisions more accurately and swiftly.
Critical Applications of Automated Vision Inspection Solution by Shubham Automation
Our automated vision inspection solution PCC ACCURA provides advanced technology with enhanced performance image processing in required applications. Our solution offers accurate color matching, verification, pattern recognition, pre-processing inspection, verification, and surface inspection to ensure the delivery of consistent, higher quality products.
The PCC ACCURA solution enables completeness and correctness of products for example filled bottles in the Food, FMCG, and Pharma industry for challenges in the diverse check-points. These check-points cover loose cap, label inspection, label presence and absence, label mix-up as well as label position inspections. The assessments cover the checking of product dimensions, product defects, and label printing.
Further, the solution can be easily integrated with any of the packing line machines with modernized cameras and multiple lines right through our PCC ACCURA software and the latest hardware components. It uses an industrial PC with a touch display for the efficiency of operations and view.
The Advantages of Automated Vision Inspection Solution
The foremost benefit is the boost in product quality. Sample testing can be substituted with comprehensive and 100% quality checks reducing the overall review efforts. The manufacturer is entirely assured and can guarantee a 100% perfect product delivery, which is especially significant in safety-critical products.
Secondly, automated vision inspection processes can reduce the overall production costs, mainly when applied in early production stages. Most of the time, defective parts or components are removed from the production processes. However, in some cases, removed parts are automatedly re-introduced in the production process, saving material costs. So, vision inspection technology resolves the trade-off amid raising quality as well as cutting overall costs.
Its further benefits are as below
- Superior and higher speed inspection
- A lower percentage of mistakes and errors
- Comprehensive and 24×7 operations
- Less to no dependency on human resources
- Quick defect detection
- Tolerance inspection
- Alignment feedbacks
- Component measurement
- Part presence, absence, and orientation
- Swift print verification
- Avoids product recalls
- Reduces downtime
- Eliminates false-rejects
- Finally, it increases the production line efficiency
At Shubham Automation, we completely understand that all organizations require being the best. Further, we value their production efforts, manufacturing infrastructure, and costs to offer the needed quality output to lead their product categories successfully.
Our range of critical quality assurance solutions like PCC ACCURA facilitates organizations like you to put off errors, mistakes, defects, and issues that offer nothing but the best solutions to our clients and their end-users. We are always our client’s Quality Assurance Heads in any of the sectors or domains we provide our automated solutions.
Sustaining and enhancing quality assurance stays at the heart of any manufacturer who desires to create a long-lasting relationship with its customer base. So it is relatively more straightforward than if your target marketplace can rely on your capability to without fail produce products that meet their desires levels of quality.
The approaches used by companies vary across the board but eventually finding the most precise and cost-effective technique of offering quality assurance is the final objective. For quite a long time, the manual inspection of the manufacturing procedures was seen as a dependable approach to preserving quality standards. But even the most effective professional is prone to make errors, and the repetitive nature of the work adds to the cause of these mistakes.
How Vision Inspections can Enable High-Speed Production Lines
The technology has moved on very drastically over the past couple of decades, with modern 2D, 3D, and barcode reading systems increasingly utilized by diverse manufacturing companies. However, there is still some uncertainty from some companies being unsure with this techniques adding value. However, with the advances in technology, vision inspections can be carried out enormously quickly on high-speed production lines; more perfectly than a human can do it and with swiftness compared to the human eye.
Introduction of Standard Machine Vision Inspection Systems
Even with the introduction of standard machine vision inspection systems, there was some indecision around facilitating them into the currently active manufacturing processes. Despite the opportunity to trim down wastage and boost data surrounding the production line, they were seen as an inadequate solution, more expensive, and challenging to integrate into manufacturers’ current systems. Here is where PCC ACCURA, an Automated Vision Inspection Solution by Shubham Automation, came into the picture to overcome challenges.
PCC ACCURA – Automated Vision Inspection Solution by Shubham Automation
Recognized most excellently for its vision inspection systems, Shubham Automation’s automated vision inspection solution PCC ACCURA provides modernized technology with superior performance image processing in several applications particularly in production and packing areas.
Shubham’s PCC ACCURA offers accurate color matching, quick verification, pre-processing inspection, pattern recognition, completeness verification, coding correctness, shipping and surface inspection to ensure that the final delivery of products is consistent with higher quality.
PCC ACCURA is shaped as a tailored vision inspection system that performs for completeness and correctness of products for example filled bottles for challenges in the diverse check-points. These check-points include loose cap, label position and inspection, label presence and absence, label mix-up, and overprinting assessments for both the products’ front and back labels.
What are the Gains from Vision Inspection Solutions for Quality Assurance
A vision inspection solution that has been accurately installed and calibrated will be precise, quick, and trustworthy. Automated quality assurance and control with vision inspection solutions have many added business gains when matched to manual inspections. The former can run continuously 24 hours and 7 days a week, and it does not require any of the tea breaks. And further, it does not tend to suffer from fatigue like human resources do and are a lot more precise, saving additional time as well as efforts.
So, the time and monitoring efforts saved by running manufacturing processes 24/7 without any breaks or changing shifts cover the cost of automated vision inspection solutions very rapidly. Further, as per the global reports, the machine vision inspection market is liable to be a value of 15 billion USD by the year 2022.
On the same side, Shubham Automation with PCC ACCURA is constantly enhancing its technology year-on-year and facilitating manufacturers with a significant competitive edge. So, Shubham, with its PCC ACCURA vision inspection solution, promises to assure the quality assurance desires of all categories of organizations across the globe.
The objective behind effective quality assurance and a comprehensive inspection is to enable reliable products. Delivery of reliable products encourages your customer’s reliance and long-term loyalty. With our unique PCC ACCURA solution, which is an automated vision inspection system, we check an extensive range of properties to preserve the quality of your products. A step further, with its remarkable flexibility, versatility, and compliance, the solution can check numerous quality features defined by you or your clients.
Suppleness and Versatility in a Single Automated System
PCC ACCURA provides multiple application modules and work with multiple cameras for diverse check-points dealt by single software and hardware. It facilitates to inspect the presence of a range of components of the product, like package inserts, pipettes, blisters, and bottles, just as effortless as enabling the integrity of the packaging and contents.
At Shubham Automation, we can determine the practical module for the applicable vision inspection by having sample testing. On the other hand, for a comprehensive safety package, it is possible to blend quality control systems that enable identification tasks and fill inspections. This scenario facilitates us to make sure optimal quality inspection for your specific products. If required, even a 360° review model can be enabled by customizing our vision inspection solution.
A Bespoke Vision Inspection Solution Enables Versatile Check Points
PCC ACCURA is designed as a bespoke vision inspection system that performs completeness and correctness of filled bottles for confronts in the varied check-points. These check-points comprise the loose cap, label presence and absence, label position and inspection, label mix-up, and overprinting assessments for both the products’ front and back labels.
Criteria such as shape, color, and precise dimensions of the filling material can signify quality features just as much as uncovering contamination, foreign bodies, and overfilled blister pockets. Foils that are applied out of position or damaged demoralize customers’ confidence in your product and be safeguarded by vision control. Further, the solution can be applied to checking-out all types of cartons, pouch, containers, carboys, barrels, and bulk bags.
How PCC ACCURA Enables Quality Assurance with Prominent Benefits
The PCC ACCURA solution covers each control function and can be enabled as per individual customer needs without added technology efforts. This scenario minimizes the time needed to integrate the system and adjust it to new formats and control operations significantly and positively affects system accessibility and total operating costs (TCO).
PCC ACCURA can run constantly, and it does not need any of the tea breaks or suffer from fatigue like human resources do, saving added time, money, and efforts. The most prominent benefits that you can have if you choose PCC ACCURA are:
- Overall Cost Reduction
- Improved Uptime
- Production Enhancements
- Superior Inspection of Parts
- Complete Customer Contentment
- Boost Efficiency and Worth of Production Systems
Industries that highly utilize Automated Vision Inspection Solutions
At Shubham Automation, our several manufacturing clients from different industries are using PCC ACCURA as a solution to enhance the quality and security of their products. Some of the client industries are as below:
- Consumer Goods
- Chemical and Pesticides
- Food & Beverages
Finally, manually inspecting substantial defects is not always trustworthy and is highly labor-intensive. To overcome these restrictions, Shubham’s Automated Vision Inspection Solution PCC ACCURA utilizes image processing techniques that are compelling enough to advance quality and boost production rates drastically across different industries. So, PCC ACCURA delivers a higher performance inspection model for identifying defects and errors on a real-time basis with all applicable versatilities in a single system.
With the continuation of all the COVID-19 pandemic disruptions, the health and safety of our employees, partners, and the clientele at Shubham Automation is our highest priority. At the same time, the top management and employees at Shubham want to restate that we are always there for our stakeholders. Shubham Automation has been considered a significant technology and business unit even actively working for its clients during these challenging times. We are more loyal than ever to serve our customers with automated quality assurance solutions, many of whom are on and at the front lines against this COVID-19 crisis each day.
How Shubham Facilitates the Roll-Out of Vision Inspection Solutions even in COVID-19 Outbreak
At Shubham, we are the specialists in enabling superior Vision Inspection Systems that provide state-of-the-art technology and automated quality. Our newest generation of vision inspection solutions is enhanced in every way to be swifter, more hygienic, safer, competent, integrated, and effortless to maintain. No matter how you select to look at it, we have got you covered with all the technical features and business functionalities, even enabling social distancing measures as a quick response to the COVID-19 Outbreak.
Automated vision inspection solutions are built to cater to numerous quality assurance processes such as packaging, manufacturing, sorting, assembly lines and other automation applications. These solutions have been shaped to meet superior and high-speed quality control requirements for the complete range of product inspections.
The key to Shubham’s capability to produce such quality Vision Inspection Solutions and roll-out them globally is our detailed design process. Every solution we design has reliability, steadfastness, and effortlessness in use applicable to your product requirements. This is a diverse approach compared to most of the market leaders and competitors who don’t take the time to purposely design every solution so that it can be customized and straightforwardly rolled out. We go all the way through similar but personalized design procedures for a diversity of systems, and this is what allows us to roll-out our quality assurance solutions across the globe.
PCC ACCURA – Automated Vision Inspection Solution by Shubham Automation
Known best for its vision inspection systems, Shubham Automation’s automated vision inspection solution PCC ACCURA offers cutting-edge technology with superior performance image processing in needed applications. This incorporates automated inspection and identification, answering to all the quality control problems. Further, our vision inspection solutions offer precise colour matching, verification, pattern recognition, pre-processing inspection, completeness verification, and surface inspection to our customers to ensure the delivery of reliable, high-quality products.
Shubham’s PCC ACCURA is designed as a custom vision inspection system that performs for completeness and correctness of filled bottles in Food, FMCG and Pharma industry for challenges in the following check-points which cover loose cap, label inspection, label presence and absence, label mix-up, label position and over printing inspections. These inspections are for both the front and back labels of the specific products.
A step further, our PCC ACCURA solution can be effortlessly integrated with any of your packing line machines. It is incorporated with several modernized cameras and numerous lines right through our PCC ACCURA software and advanced hardware. It utilizes industrial PC with a touch display for the effectiveness of operations and view.
Key Application Benefits of PCC ACCURA Solution
So, PCC ACCURA not only enables quality assurance, but also boosts line accuracy, which avoids product recalls, reduces downtime, eliminates false-rejects, and thereby persistently increases production line efficiency. Our solution is applied for checking-out all categories of bottles, cartons, pouch, containers, carboys, barrels, and bulk bags. Further, our PCC ACCURA solution enables automation at every level with round the clock processing, minimize manpower and use of additional resources.
Shubham Automation supports you for global roll-outs with benchmarked quality assurance solutions, automated systems, advanced technology and a fool-proof solution development methodology. All these initiatives and assurances consider all the aspects required to create a successful roll-out. Our vision inspection solutions promise to satisfy the desires of all categories of organizations around the globe, moving ahead with a strong response to the COVID-19 Outbreak.
The average cost of a product recall in specific industries is in millions when we measure the overall time, efforts, and costs of recovering the recalled products. Additionally, these expenses are even more costly when we consider the final consequences of product recalls. A lost market share, the effect on customer loyalty and several other concerns must be thoroughly counted to evaluate a recall’s impact on your company brand.
Despite the underlying problems that are sources to product recalls, there is no particular reason why recalls should be as regular as they are today with advanced infrastructure and the latest technologies. Organizations should take the assistance of right vision inspection solutions that are highly competent in finding and reporting problems before these products finally leave the plant. In this particular blog, we will discuss and explore the significant impact product recalls can have on a company brand and suggest solutions to keep away from future product recalls.
Harmful Impacts of Product Recalls
- Involved Costs
Let’s initiate with costs. The cost of a product recall is not equivalent to the cost of the exhausted product alone. It also comprises the costs of precisely finding, transporting, and demolishing that particular product, plus the expenses linked to your supply chain’s distraction. All these cost factors incorporate business interruption, reverse logistics, alerts to relevant parties (customers, supply chain, regulatory bodies, and consumers) along with added labor costs to perform all these tasks which have not been included in the budget by the involved stakeholders.
- Customer Loyalty
When customers lose reliance on a company brand, it eventually translates to losses in sales and reduction in market share, mainly if the product recall is because of undeclared ingredients and allergens. In a recent report by the food industry, around 55 percent of consumers said they would provisionally or temporarily switch brands due to a product recall. Furthermore, about 15 percent said they would by no means buy the recalled product for a second time, and around 21 percent would shun buying any product from that specific brand.
Further, even if you don’t face a product recall, unsatisfactory experience with your product because of factors like mislabelling or miscoded products will impact the brand and hurt its probability of becoming a successful product with momentous sales.
Frequent Causes for Product Recalls
Despite the efforts, time, and expense connected with correcting these problems, recalls are not at all rare. According to surveys and reports, there have been a high number of recalls each month due to labelling mistakes alone so far in the year 2020. The frequent issues for recalls comprise:
- Undeclared Allergen Information: Whether allergen information is scribbled or expelled from the packaging.
- Mismatched Product and Packaging: Packaging is executed with the incorrect product version by error and has to be recalled.
- Mislabelled Lids and Packaging: The lids or labels are made functional to the mistaken packaging, which outcomes in the form of a recall.
Enhancing traceability for swifter identification and reporting of these problems can assist you in evading expensive product recalls and trim down products as well as plastic wastes.
How to Avoid Product Recalls
Finally, coming to the solution of this problem, Shubham Automation, with a decade of experience designing Vision Inspection Systems has developed and enabled an automated vision inspection solution called PCC ACCURA.
PCC ACCURA is compact and state-of-the-art designed product which can be easily integrated with any of your packing line machines. It is integrated with multiple advanced cameras and numerous lines right through our smart eye software. It uses 15.6 inch industrial PC with a touch display for simplicity of operation as well as view.
Further, it utilizes modernized tools and advance illumination for precise reading on shiny surfaces. It acts like an intelligent eye checking solution for comprehensively checking-out the final packaging information on products to uphold information correctness rather than depending on human resources to execute this job manually.
The solution advances and boosts line accuracy as well as quality assurance. It avoids recalls, trims down the overall downtime, false-rejects, and declines any type of rework, thereby continuously increasing production line efficiency.
PCC ACCURA facilitates several specific categories of automated inspections. Here are a few we have included:
- Enable checking of all types of cartons, bottles, pouch, containers, carboys, barrels, and bulk bags for finding errors.
- Printed batch code and expire code is examined to confirm whether it is completely precise or not.
- The solution can ensure the cap fitting, cap pop-up, label presence, and complete alignment.
- It can also identify a mix match of labels and products in the explicit shipper.
- Finally, it facilitates reports such as precise performance reports, audit trail reports, batch-wise reports, hourly reports, production reports, and specific fail image analysis.
At Shubham Automation, our range of quality assurance solutions like PCC ACCURA facilitates organizations like you to prevent recalls for your brand that deliver nothing but the best experience to the client, the involved supply chain stakeholders, and the end consumer.
Our dynamic quality assurance team is always our client’s default Quality Assurance Heads with complete responsibilities in any of the sectors or domains we provide our automated solutions.