Modern packaging lines rely heavily on high-speed automated vision systems to verify labels, lot numbers, expiration dates, and 2D serialization matrices. Validating these systems involves unique challenges bridging the gap between mechanical equipment and complex software.
Key Requirements for Vision Systems
Your URS must clearly define the parameters for the vision system, including the minimum font size readable, the required line speed (e.g., 300 cartons per minute), and the expected lighting conditions.
The Challenge of "Known Bad" Samples
The most critical part of validating a vision system is proving that it correctly rejects defective products. This requires creating a library of "Known Bad" (challenge) samples.
- Missing Print: Labels completely missing the lot/expiry block.
- Poor Print Quality: Smudged or partially obscured 2D matrices.
- Incorrect Data: Correct format, but wrong lot number.
During the OQ and PQ phases, these challenge samples must be introduced into the line to ensure the vision system consistently identifies and mechanically rejects them without stopping the line erroneously.