WCA September 2012

3.5 Test Results Taymer’s Print Verification System has been tested in the industry extensively on different products, print messages, and using types of printing methods. The two authors worked closely with Commscope in Claremont to bring this QA technology to the plant. The before and after print defect data was recorded. After one year of use, print defects were reduced by over 50%. The reasons were as follows: • Minor print quality issues were caught before they became an actual defect. For example the operator adjusted the printer or fixed cable alignment • Printer maintenance was initiated before the printer actually malfunctioned because the operators received very current feedback on print quality • Incorrect print legend was identified before the entire run was misprinted 3.6 Sample Images Figures 3-5 are sample images or screenshots of print defects found by the PV optical system on different products. Conclusions With a Print Verification System, the print legends on the cable can be inspected thoroughly for defects. The system provides several benefits: • Suitable for any type of products – wire/cable/hose/ pipes/bars/plates/stranded product • Suitable for any type of printers – inkjet, ink wheel, hot foil, laser, indent/emboss • Ensure the customer will not get defective products, improving customer relationship and confidence • Reduce reprinting and eliminate consumable waste resulting in material cost and labour cost • Assist in internal improvement to production process to reduce defects

❍ ❍ Figure 3 : Missing print detected at 900ft/min

❍ ❍ Figure 4 : Poor print quality detection at 200ft/min

❍ ❍ Figure 5 : Screenshot of print quality comparison

line is still running. If the print quality is degrading below the threshold, the operator can immediately adjust the printer to improve the quality. Also, operators can use the PV system at the beginning of the run to set-up the printer and check to ensure the print legend is correct. The PV system allows changes to be made on the fly, greatly reducing reprint of the cable post production. Quality Assurance The system will capture images of the printed cable at high line speeds, and save the images of the print defects to disk for use in quality reports. The PV system’s display makes it easy for engineering and production supervisors to examine the defect without having to see the defect itself. Defect locations are recorded together with the image allowing for easy report generation and further analysis. 3.4 Limitations There are a few limitations to the print verification system. • For different types of cable surface (round/twisted profile), and fonts, the same print legend may look different. Therefore, different templates are required for different types of cables • Lengthy print legend can also twist out of the camera view, resulting in missing characters. There is a high chance of this happening on twisted pair wires • Since the camera is looking at the surface, water droplets/grease/dust particles would show up affecting the print legend resulting in false defects. To compensate for them, the system would need to decrease the quality threshold or an air wipe is necessary

Acknowledgments

Special thanks also to the IWCS staff for making this template available for this year’s publication.

Craig Girdwood Taymer International Inc 145 Renfrew Drive Markham Ontario Canada L3R 9R6 Tel : +1 905 479 2614 Email : craig.girdwood@taymer.com Website : www.taymer.com

Brian Franklin Commscope Claremont

North Carolina, USA Tel : +1 828 324 2200

Email : info@commscope.com Website : www.commscope.com

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