Quality, accountability and product reconciliation are production mandates at Eli Lilly, which is why the leading pharmaceutical manufacturer has automated its mechanical vial counting process. The company enlisted a system integrator that specialises in vision system integration, commissioning, installation, and validation.
Together, they co-developed a ground-breaking tray inspection system using a colour visual inspection process powered by In-Sight machine vision sensors from Cognex Corporation.
The quality inspection system combines machine vision with automatic tray handling, to enable 100% accountability of products
While Eli Lilly’s mechanical counter provided only vial count, the new system uses machine vision to perform a visual inspection that detects fallen vials, identifies missing flip-seals, and verifies cap colour on each vial. As a result, the tray inspection system improves product quality, in addition to increasing vial-counting efficiency for 100% product reconciliation.
The existing mechanical counters that were being utilised were prone to jams and that operators could easily misshandle vials around the counters resulting in a count discrepancy. This made identification of root causes for mechanical counter errors difficult to identify. A major benefit to the new tray inspection system is that root causes to count deviations are easier to identify, correct, and explain.
To meet Eli Lilly’s requirements, the vision system has to establish a tray count, look for vials that have fallen over, check that flip seals are in place, and inspect for vials with the wrong colour caps, called strangers. After evaluating a number of systems, the system integrator selected the In-Sight 1000C colour machine vision sensor from Cognex. The sensor combines a DSP-based vision-processing unit with a 640 x 480, 8-bit progressive scan digital vision camera in a compact housing with built in communications, and a library of vision software tools.
The system integrator tested several systems to prove which could do the job, then selected the vision system based on the results. Cognex tools were found to be more robust for this application than the other vision tools evaluated, and the powerful pre-processing filters helped to achieve the desired inspection results.
The test system features an Allen-Bradley PLC that handles sequential control and logic. Communications are handled via hardwired discrete I/O (input and output), serial data transfer and Data-Highway Plus. A PanelView 1000 mounted on a pivoting arm serves as the main operator interface for program selection, fault display and maintenance functions.
The system also incorporates an industrial PC mounted within the inspection hood. The industrial PC runs a custom front-end interface.
The result is a flexible vial counting and tray inspection system that can be run by a single operator with minimal machine vision knowledge, and handles a wide range of tray sizes with minimal mechanical changeover. The inspection can run Lilly’s largest tray configuration at over three trays per minute which equates to over one thousand vials per minute. The system speed capabilities are well within the packaging line speed requirements of 320 vials per minute.
Smart alternative for float switches ifm - South Africa
Sensors & Transducers
With the LI level sensor, you can reliably detect leakages and point levels on a permanent basis. The capacitive measuring system has no moving parts. Malfunction or maintenance issues due to deposits on the mechanical parts are therefore eliminated.
Read more...Telco sensors in the pulp and paper industry Gail Norton Instrumentation
Sensors & Transducers
The pulp and paper industry poses a major problem for most photoelectric sensors. The high level of contamination in these dusty, dirty and grimy environments makes it impossible for most competing sensors to operate and sense reliably and efficiently.
Read more...Precision acoustic imagers Comtest
Sensors & Transducers
To help users identify and localise ‘mechanical areas of interest’ within short timeframes, Comtest has added a unique new feature to Fluke’s ii910 precision acoustic imagers.
Read more...Efficiency and precision with IO-Link sensors RS South Africa
Sensors & Transducers
RS South Africa has its own brand known as RS PRO, which offers a choice of over 88 000 products across all industries and technologies. The guaranteed quality and breadth of this range make RS PRO the smart choice for your business.
Read more...Smart alternative for float switches ifm - South Africa
Sensors & Transducers
With the LI level sensor, you can reliably detect leakages and point levels on a permanent basis. The capacitive measuring system has no moving parts. Malfunction or maintenance issues due to deposits on the mechanical parts are therefore eliminated.
Read more...Optical fork sensor series Gail Norton Instrumentation
Sensors & Transducers
The OFS series consists of self-contained optical fork sensors that are housed in a durable, U-shaped aluminum housing, which operates in through-beam mode.
Read more...In-line process transmitter to optimise sterile processes WIKA Instruments
Sensors & Transducers
The new model DMSU22SA in-line process transmitter from WIKA helps to optimise sterile processes in the pharmaceutical and food industries, with less energy consumption, less cleaning effort ,and more safety.
Read more...Automated clean-in-place Endress+Hauser South Africa
Sensors & Transducers
A clean-in-place (CIP) process is integral to a food and beverage producer’s responsibility to deliver safe, high-quality products to consumers. However, as industries worldwide shift focus towards sustainability, CIP procedures face new challenges.
Read more...Signal conditioning is the protective armour between plant and field Omniflex Remote Monitoring Specialists
Sensors & Transducers
Measurement and control of physical properties are the foundation of all critical industrial technologies. Ian Loudon, international sales and marketing manager at remote monitoring specialist, Omniflex explains the challenges of industrial signal conditioning and the importance of safety engineering.
Read more...Precise detection of complex rotational movements Beckhoff Automation
Sensors & Transducers
The EP3751-0260 EtherCAT Box module by Beckhoff connects an acceleration sensor with an inertial measurement unit - a gyroscope. This provides accurate detection of acceleration and rotational motion in addition to shock, vibration and tilt measurement, both as preprocessed values and as raw sensor data.
printer friendly version