Cigarette Package Coding System with Real-Time Defect Detection
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Solution Overview
Problem
In high-speed cigarette manufacturing processes, there is a challenge in ensuring accurate and repeatable coding on cigarette packages, with issues such as low print quality, misalignment, and errors leading to defective products, which must be detected and removed quickly without affecting non-defective ones, while also analyzing defects for root cause identification and process adjustments.
Innovation Solution
A package coding system comprising an imprinting device, a conveyor device, an inspection device, and a removal device that works in conjunction to detect and remove defective cigarette packages with defects in the alphanumeric code, using image processing and machine vision systems to identify and isolate defective products without disturbing others, and a handling system to adjust for their absence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed manufacturing process is used to increase productivity, then production throughput is improved, but coding accuracy and print quality deteriorate
Solution Approach 1:
The system performs preliminary coding of cigarette packages at high speed, then conducts inspection and defect detection after coding but before final packaging. This allows high-speed manufacturing to continue uninterrupted while quality control is performed on already-coded products, resolving the conflict between production speed and coding accuracy.
Solution Approach 2:
An intermediary inspection system with cameras and sensors is introduced between the coding process and final product completion. This intermediary device detects coding defects without stopping the high-speed production line, allowing both high productivity and high coding accuracy to be achieved simultaneously.
2Speed
If inspection and removal of defective products is performed quickly, then defect detection speed is improved, but product handling complexity increases
Solution Approach 1:
The system replaces complex mechanical handling and manual inspection with an automated optical inspection system using cameras and sensors. Defective products are identified through image processing and automatically flagged for removal, eliminating the need for complex manual handling procedures while maintaining high detection speed.
Solution Approach 2:
The inspection system automatically detects and identifies defective coded products without human intervention. The system self-regulates by comparing coded information against required specifications and automatically signals for defect removal, reducing handling complexity while maintaining high detection speed.
3Reliability
If comprehensive defect analysis is performed to identify root causes, then quality improvement is improved, but processing time increases
Solution Approach 1:
The system implements continuous feedback by monitoring coded products in real-time during manufacturing. Defect data is immediately fed back to operators and the coding system, allowing for immediate corrective actions. This continuous feedback loop improves quality without requiring time-consuming batch analysis, as issues are addressed as they occur.
Solution Approach 2:
The inspection system performs preliminary defect detection and categorization during the manufacturing process itself. By identifying and flagging defects in real-time rather than performing comprehensive analysis after production, the system enables immediate quality improvements without adding significant processing time to the manufacturing cycle.
Data Source
AI summary
A package coding system for a cigarette manufacturing process is provided. An imprinting device imprints an alphanumeric code on each of a series of cigarette packages. A conveyor device conveys the cigarette packages in a feed direction. An inspection device is operably engaged with the conveyor device and inspects the alphanumeric code imprinted on each cigarette package conveyed by the conveyor device to determine whether any of the cigarette packages includes a defect in the imprinted alphanumeric code, and thus comprises a defective cigarette package. A removal device is operably engaged with the conveyor device and is configured to be in communication with the inspection device. The removal device is configured to remove the defective cigarette package from the series of cigarette packages conveyed by the conveyor device in response to identification thereof by the inspection device. An associated method is also provided.