Our WVI-FC and WVI vision inspection systems seamlessly integrate with other Wayne Automation packaging stages, allowing for an automated handoff of cases and baskets into the inspection test cell. Depending on the system you choose, the machine vision technology inspects the case for the proper number and arrangement of items as well as interpacking for product shipping.

If a case fails inspection, it is rerouted off-line for further evaluation or reloading. A case will fail inspection if it has missing or damaged products or interpacking. The system also captures images for offline review so you can verify your packaging lines are working correctly.

Wayne machine vision technology includes Cognex’s Insight line of 2D vision inspection smart cameras powered by machine learning algorithms. These vision systems are self-contained and flash a Pass/Fail indicator LED while in operation, allowing you to observe the pass rate for your product even without diving into the Cognex software. The system also has a user-friendly HMI that shows the inspection process with high image quality on the screen, alerting you to see which cases fail and why.

For industries that can work with individual units in the million, tight tolerances are needed to ensure small errors don’t spiral out of control. That’s why our vision systems are equipped not just to identify missing products but also to identify whether a case has been improperly loaded and even ensure interpacking and partitioners are correctly inserted. These machine vision cameras also connect to your MES system, allowing them to scan the package’s SKU to ensure the right products are in the right container.

Without automated vision systems, companies must rely on human operators to inspect each container. Manual inspectors need to complete many steps that automation makes seamless, as they must hand it off, open the flaps, check section by section, and then decide if it’s a pass or fail. Add in the need for breaks, shift changeover, and the unavoidable truth that people slow down as their workday progresses, and we see how fully automated vision systems benefit every industry, no matter how stringent.

In the manufacturing industry, we consider reliability with respect to how often the machine breaks. However, in quality assurance, we must consider how often an inspection step fails to identify a non-compliant product or produces a false positive. Human inspectors are prone to missing small details, especially if they perform a repetitive task for hours on end. With our fully automated and machine vision systems, you can improve detection capabilities and ensure incorrectly packed containers never reach the end of the line.

The initial investment in automated machine vision equipment pays dividends over time, as you save money on repairs to inferior systems or paying human operators to work around-the-clock shifts. Machine vision solutions can also help speed up your manufacturing process by streamlining end-of-line packaging. Our machine vision systems are designed to last, and all maintenance is communicated through the color touchscreen display, so you never need to guess what is required to keep your system running optimally.