Defect Mapping

    Efficient quality control with PC Industries’ Defect Mapping software

    Defect Mapping is a flexible, easy to use software module for the Guardian PQV that helps operators monitor job quality and eliminate defects. By detecting and recording defects early in the printing process, the Defect Mapping software makes it easy to correct defects post-press. It provides a true report of defect free products once job auditing is complete. Automated monitoring of product quality throughout the production process helps ensure that quality products are delivered to your customers. This increases their satisfaction and improves your bottom line.

    Inspect: Automate Defect Detection through Defect Roll Mapping

    defect_map_illo2Setup is as easy as capturing an image from the press, training the system, and beginning inspection. On systems equipped with PDF Check, the golden image from the press can be verified against a customer approved master document before inspection begins.

    During inspection, the Defect Mapping software will record defects by lane and footage for each roll or sheet. The on-screen grid display provides a graphical representation of the location of defects for each lane, with color-coded indication of the severity of each defect. The operator can view the Defect Map history and accept or reject defects while the system still provides 100% inspection. Defects are displayed side-by-side with the master image for easy comparison. The operator can easily train the system to ignore repeating, non-critical defects for a more efficient run. These settings can be saved and retrieved for later runs of the same job.

    Once the job is finished running, the Defect Map can be output to an enhanced PDF report, which logs key job information, images of each defect, and the corresponding master image. The Defect Map can also be saved and automatically transferred to an Edit Workstation, Audit Rewinder, or other finishing machine.

    Edit: Remove Defects Before They Reach the Rewinder with the Editing Workstation

    To enhance quality control, information collected from the press run on the Defect Map can be edited at a dedicated Defect Map Workstation, which can be located anywhere in your facility. With the Defect Map Workstation, the Defect Map is automatically transferred once the job is complete. The operator can confirm or remove defects from the Defect Map before the job is sent to a post press process for defect correction. The productivity of the slitter/rewinder is improved by eliminating unnecessary starts and stops due to non-critical defects. Editing workstations can accept information from multiple presses, and feed multiple slitter/rewinders.

    Audit: Finish with Perfect Product using the Control Workstation

    The Defect Map Control Workstation integrates with nearly any finishing machine, including slitters and rewinders. The system includes the timing circuitry and output controls necessary for machine control, flagging or marking devices, or defect diverter timing. Additionally, for sheet-fed and similar applications, sheets can be sorted based on several criteria, including position of defect on the sheet and type of defect.

    In a typical rewinder application, the Control Workstation will signal the machine to decelerate and stop the defective print at the splicing table or other preferred location. Placement is very accurate, even at high speeds. The defective label is displayed for review on the monitor, allowing the operator to toggle between the sample and master display and magnify defects.

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