4-cavity ice-cream tub: faulty labels 0.9% → 0.05%
VQ-Vision was added to an existing SE-250 line; tubs with faulty labels were separated before packing and no case has been returned since commissioning.
- 0.9% → 0.05%Faulty labels
- 6 → 0Case returns / month
- 2% → 100%Inspection coverage
01Challenge
The customer, producing 1 litre ice-cream tubs for a retail chain, received case returns because of a single tub with a faulty label in the case. Visual checks were done on samples at the end of the shift and thousands of tubs were packed before the 0.9% fault rate was noticed.
02Solution
A VQ-Vision dual-camera station and an air-jet reject unit were added to the outfeed conveyor of the existing SE-250 line; label presence, ±0.3 mm position and seam were checked on every tub. Per-cavity statistics revealed a vacuum leak on cavity 3 on the first day.
03Result
The faulty tub rate reaching packing fell to 0.05%; no case was returned in the first month after commissioning. After the cavity 3 leak was fixed, the rate of faulty labels coming out of the mould also fell from 0.9% to 0.3%.
Result metrics
- 0.9%→0.05%Faulty labels
- 6→0Case returns / month
- 2%→100%Inspection coverage
Before / After
BeforeAfter
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