01
Problem
The manufacturer required a system to identify and remove packs entering the line in the wrong orientation, products from different production recipes mixed together, and packs with incorrectly positioned lids.
02
Solution
An inspection and reject system was integrated at the production line exit to check pack orientation, conformity with the active production recipe, and lid position. Products identified as non-conforming were automatically removed from the line at the rejection point.
03
System architecture
Mechanical Fabrication → Mechanical Assembly → Electrical Fabrication → Electrical Assembly → PLC Programming → HMI Design.
04
Technologies
05
Result
Products with the specified defects were automatically separated at the end of the line, preventing them from proceeding to subsequent packing and dispatch stages. The system established a quality control framework to help manage product mix-ups and incorrectly positioned lids.
The project covered the development of a product inspection and automatic rejection system tailored to the wet wipe production line. The scope included:
End-of-line integration: Positioning the inspection and reject station to suit the existing product flow.
Pack orientation inspection: Identifying incorrectly oriented packs and directing them for rejection.
Production recipe verification: Checking products against the active production recipe and rejecting products belonging to other recipes.
Lid position inspection: Checking whether the lid on each pack meets the specified positioning criteria.
Product tracking and rejection coordination: Matching each inspection result to the corresponding pack to ensure the correct product is removed at the rejection point.
Automation and mechanical integration: Coordinating the inspection process and rejection mechanism with the production line.
Testing and commissioning: Verifying inspection and rejection performance across different non-conformity scenarios.
These activities aimed to standardize end-of-line quality control, automate the rejection of non-conforming products, and reduce the need for manual operator inspection.