A global brand of personal care products found some of its own plant staff were breaking the rules, letting products with incorrect or misaligned labels slide through the vision system. Sometimes, an operator might be at the end of a shift, or have a quota to fill and be at risk of running out of time. Whatever the reasons, the manufacturer discovered that some plants employed clever, and often low-tech strategies for bypassing the vision inspection process. Sometimes the plant staff would simply shut off the vision sub-system and let the products go through without inspection. Other times the staff would place an image of a good product in front of the camera; naturally, the products "inspected" this way had a 100% pass rate!
When this company explained the issue to CI Vision (Aurora, IL), one of their requirements was a mechanism to prevent plant staff from bypassing the vision system. "They needed something fool-proof," explains Tom McLean, COO at CI Vision. McLean calls CI Vision's fool-proof strategy "Anti-Vision Circumvention Technology". It's one of the interesting new features of the company's Pro Series, a line of inspection systems for contract packagers.