W. H. Leary and EyeC Technology sat down with Nick Stober, Director of Quality Systems and Compliance, and Wanda Speer, Marketing Manager, from Colbert Packaging, Kenosha, WI, USA, to discuss their print inspection solution and the impact it has made on their overall business.
“We have used the LearyVIEW Print system with EyeC as a marketing tool. We feel that is has helped us gain business that that we would not have been able to get before. It has given us an advantage over a competitor because of their lack of technology. On the operations side, it has helped us improve our processes and make them more efficient while delivering quality product.” – Nick Stober
Q: What were Colbert Packaging’s initial reasons for investing in a print inspection vision system?
A: Colbert Packaging sought to integrate a camera vision system to enhance its printing quality control into their folding carton process. This was especially crucial for the large number of their pharmaceutical customers that require stringent defect scanning. Additionally, monitoring for printing defects beforehand prevents costly returns, re-work and potential for the loss of a customer. Partnering with Leary and the solution they offer with EyeC made sense as the company already used Leary’s gluing and quality systems, making the addition of a vision solution a seamless addition.
Q: What specific goals did Colbert aim to achieve with this investment?
A: The system serves both operational and marketing advantages. It has helped Colbert gain a competitive edge in their market, opening new business opportunities. On the operations side, it has streamlined processes, improving efficiency and defect detection. The system allows Colbert to identify and address upstream printing issues, significantly reducing manual labor for sorting. That task previously required an entire team over a week to complete, but now we utilize technology and automation to verify quality standards are achieved.
Q: Has the vision system contributed to cost savings and operational efficiency?
A: Absolutely. Previously, if a defect was found, entire batches were discarded due to uncertainty over which units were affected. Now, the vision system isolates defective cartons, saving materials and labor. This has eliminated the need for extensive manual sorting and has significantly reduced production downtime.
Q: How has the system performed compared to expectations?
A: It has exceeded expectations. An unexpected benefit was the ability to inspect fully folded and glued cartons, not just flat ones. This additional capability has further enhanced quality assurance and efficiency at our plant as a whole.
Q: Has the investment in vision systems led to increased business opportunities?
A: Yes. The system has helped attract new business, particularly from large pharmaceutical companies that prioritize quality assurance. Existing customers have also expanded their business with Colbert due to the advanced inspection capabilities.
Q: How does the vision system align with Colbert’s sustainability initiatives?
A: By minimizing rework, reducing material waste, and optimizing workforce efficiency, the system contributes to Colbert’s sustainability goals. Improved production efficiency directly translates into a more sustainable manufacturing process.
Q: Why did Colbert choose LearyVIEW Print Solution over other options?
A: The system’s ease of integration with existing equipment was a key factor. Unlike other print inspection solutions that require additional space, LearyVIEW Print adds only 46 cm (18 in) to the gluer, which is crucial for space-constrained facilities. Moreover, Leary’s technical support ensures minimal downtime, a critical factor in production environments.
Q: How was the installation process?
A: The installation was straightforward. Leary delivered the machine in one piece, split the gluer, inserted the unit, and reassembled everything seamlessly. The upgraded new drive system installs in the same efficient way, with production resuming the same day.
Q: How has the LearyVIEW Print system impacted production?
A: The system has significantly improved carton handling, eliminating skewing issues and allowing seamless adjustments for different carton sizes. Operators appreciate its flexibility and reliability, and any minor challenges were quickly resolved with Leary and EyeC’s technical support.
Q: What is the maintenance process like?
A: Maintenance has been minimal. The carrier belts require little to no upkeep, and any belt changes are quick and simple. If needed, the entire assembly can be swapped out efficiently.
Q: What are the disadvantages of not having a print inspection system?
A: Without print inspection, defective products could be unknowingly shipped, jeopardizing customer relationships and compliance in the highly regulated pharmaceutical industry. The system also provides flexibility in production, allowing work to be shifted between facilities to balance capacity constraints.
Q: Who can benefit from implementing a print inspection system like LearyVIEW Print?
A: Any company printing cartons can benefit. The return on investment depends on the frequency of required inspections, but industries with all quality demands can find value in a fully automated inspection system. The EyeC inspection technology with Leary integrations, has delivered large pharmaceutical customers pushing business to Colbert because of the ability to inspection product in a way that other companies cannot inspect.
Q: What standout features of the new hardware system design have been most beneficial?
A: The enhanced flexibility in track adjustments has significantly improved handling of various carton sizes, eliminating previous limitations. The system now accommodates both very wide and very narrow cartons with ease, ensuring precise inspection across all product types.
With its investment in LearyVIEW Print inspection technology, Colbert Packaging has strengthened its commitment to quality, efficiency, and customer satisfaction. The system has not only streamlined internal operations but also positioned the company as a leader in high-quality, defect-free packaging solutions.
Learn more about this solution. https://www.whleary.com/products/quality-assurance/camera-inspection/learyview-print/
