Cognex Vision Systems – Enabling packaging companies to select the right machine vision partner

According to the United States Association for Packaging and Processing Technologies (PMMI), labor requirements, automation and production efficiency are the top three priorities for consumer packaged goods (CPG) companies. Labor demand and the scale of automation can drive productivity improvements, but given the current difficulties in recruiting workers and the sharp rise in labor costs, automation seems to be the best channel to solve the current dilemma.

To address these labor constraints, enable automation, and improve production efficiency, packaging manufacturers are implementing new hardware and software technologies. Today's machine vision hardware and software are powerful, easy to use, and less costly, and by equipping packaging lines with machine vision, they can not only support automation goals, but also help meet automated quality assurance needs.

Cognex Vision Systems – Enabling packaging companies to select the right machine vision partner

　　As a result, more and more packaging manufacturers are experimenting with new hardware and software technologies. These new technologies are often powered by machine vision. Machine vision addresses a wide range of applications, including robot guidance, code inspection and validation, data collection, and quality inspection. By equipping your packaging line with machine vision, you can not only support your automation goals, but also help meet your automated quality assurance needs.

However, the solution needs to be made up of different products and technologies that are custom-produced and developed, which requires the packaging company to choose different partners to work together. However, choosing the right machine supplier can be challenging. So where do packaging companies start? The following guide is a 3-step guide that makes it easy for packaging companies to select the most suitable machine vision partner.

【Step 1: Clarify the scope of the project】

When installing a new machine or packaging line, it is very important to be clear about the performance objectives of the project, identify the machine/packaging line functions required to achieve these goals, and develop an execution plan, as well as a budget and timeline. Develop project specifications based on input from operations and packaging line technicians and specify the following:

　　When starting a machine vision project, it is often necessary to work with multiple partners, including original equipment manufacturers (OEMs) or machine builders (with a focus on custom machines), vision technology providers, and system integrators. But regardless of the number of suppliers, it's important to involve these suppliers early in the project development process, to develop a timeline of project milestones that are agreeable and achievable to all parties involved, and to clearly assign responsibilities to ensure that the project stays on schedule.

Building a strong partnership early in the project will help ensure a seamless design and integration process that enables the system to operate in an optimized manner, achieve excellent overall equipment effectiveness, and meet output, productivity, quality, traceability, and data collection goals.

[Step 2: Confirm the division of labor between different roles]

1. The role of OEM/machine manufacturer

When considering which OEM or machine builder to choose as a partner, it is first necessary to choose a partner who has extensive experience in the industry and type of product in which it is engaged. If the industry, product type, or packaging format is new to the supplier, be sure to invest extra time in gathering and collating the knowledge needed to execute the project. Regardless of experience, be prepared to closely monitor project schedules, costs, and equipment design processes to ensure that no important details are overlooked to avoid the need for redesign or negatively impacting project delivery and budget.

In addition to relevant experience in the industry, product type and packaging format, suppliers should be evaluated in terms of:

▪ Reputation.

▪ History and financial status

▪ Staff size and expertise

▪ Customization capabilities

▪ Order backlog

▪ Turnaround time

▪ Support (training, maintenance, spare parts, etc.)

Answer the above questions to determine if the supplier has the capacity to deliver the equipment on time and on budget, ensure a seamless start-up, and keep the machine/line running efficiently. It is also important to understand the extent to which the vendor's service delivery matches the project's needs and budget.

The degree of customization is another important consideration, as costs and turnaround times often increase as the degree of customization increases. Regardless of the source of the vision technology, OEMs/machine builders need to have the ability to integrate rejection devices into their machines in order to collect any defective products identified by the system for rework or disposal.

2. The role of the system integrator

More complex projects, such as packaging lines with multiple machines, often integrate many systems. In this case, system integrators can offer a number of advantages. System integrators have the expertise to provide a complete solution, including installation and seamless start-up, and accelerate time to market. System integrators often have extensive project experience, extensive application knowledge, and new technologies. They are also familiar with numerous OEMs/machine builders, machine vision providers, and control systems.

For example, the Cognex Partner Services Integrator Network can:

▪ Design, manufacturing, and packaging vision solutions

▪ Customize automation equipment according to specifications

▪ Integrate hardware and software into existing systems

▪ Develop quality control and worker safety measures

▪ Comply with local regulatory requirements

▪ Provide a standardized system to replicate in other plants, including in other parts of the world

When selecting a system integrator, you also need to ask many of the same questions asked above for OEMs/machine builders and make decisions based on the answers, including reputation, business history, profitability, flexibility, staff size and expertise, certifications, training offerings, and ongoing service support, maintenance, and upgrades.

3. The role of the visual provider

When a packaging machine or packaging line requires machine vision to meet performance targets, machine vision technology providers should be involved early in the project to meet product development, integration, and lifecycle requirements. This ensures that the vision system integrates seamlessly with the machine/packaging line/factory and meets the expected performance targets, while also reducing the risk of design errors, implementation delays, and cost overruns.

Machine vision providers typically invest heavily in R&D, offer patented technology, and are able to provide engineering support on a global scale. By partnering with a machine vision provider that offers these benefits, you get access to a wide range of capabilities.

For example, as a vision technology provider, Cognex can:

▪ We offer a wide range of industry experience with successful applications in almost all industries

▪ Global expertise is provided to ensure that when installations are replicated in other parts of the world, equipment can be redesigned as needed to meet the specific requirements of the destination country

▪ Technical expert support and new technologies are available

▪ Help assess project feasibility and develop vision system specifications to ensure that important details are not overlooked and that the equipment is meeting performance targets

▪ Assist in project justification and project budgeting

▪ Minimize the time invested in developing, redesigning, and debugging vision systems

▪ Shorten lead times

▪ Confirm the proof of concept

▪ Optimized hardware and multilingual software combinations for customer applications

▪ Training, service and support are available worldwide

The right vision technology provider can bring advanced software, image engines, vision systems, and barcode reading that are easy to integrate and operate. These state-of-the-art products, combined with pre-sales support and global market coverage, significantly reduce the time OEMs and machine builders spend developing, redesigning, and commissioning vision systems. Once the machine/packaging line is up and running, the installation of advanced, reliable vision and recognition technology also means that the likelihood of problems is greatly reduced.

【Step 3 Machine Vision Project Checklist】

Finally, confirm the details one by one according to the table below and select the most suitable machine vision partner

　　So, when installing a new packaging machine or line and equipping it with machine vision technology, there are a number of questions that need to be asked first, and the answers to these questions will ensure that you choose the right OEM, vision technology provider, and/or system integrator partner. Of course, it is important to involve these suppliers as early as possible in the design phase and to share details and expertise in a timely manner after the project has started, which is key to ensuring the success of the project's implementation and operations.