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Guides
False rejects cost good product and train operators to ignore the reject bin. Most of them come from the light, the part position or the settings, not the camera.
A false reject is a good pack the station throws out. An escape is a bad pack the station lets through. They pull in opposite directions: tighten a setting to stop escapes and false rejects climb, loosen it and escapes climb. A station is only tuned when both numbers are tracked on their own, from real production, not from one combined reject rate.
LEDs dim as they age and as they warm up. Red and amber LEDs lose more output with heat than blue ones, so a job taught on a cold light in the morning can drift by afternoon. Strobe the light, let it warm up before teaching, and check the image brightness on a schedule.
A pack that arrives tilted, shifted or spinning looks like a different pack. Guide rails, a steady conveyor speed and a trigger sensor placed close to the camera fix more false rejects than any software change.
Limits taught on ten perfect samples reject normal variation. Teach on a real spread of good product from several lots and shifts, then set limits with room for that spread.
A new ink, a new label supplier or a new artwork version can shift contrast or position. Treat any packaging change as a reason to re-check the station.
Dust, product splash and condensation soften the image slowly. Add lens and window cleaning to the sanitation checklist.
If the reject arm fires late or early, the wrong pack goes out. Test reject timing with marked packs at full line speed.
Change one thing at a time and watch both numbers for a full shift before the next change.
FAQ
It depends on the product and the check, but a station should run low enough that operators trust the bin. If people stop checking the rejects, the rate is too high.
Not as a first step. Loosening a limit can let real defects through. Find the cause first: light, part position, or teaching samples.
Sometimes, when good product varies in ways rules cannot describe. For stable defects, fixing the light and the part handling is usually faster and easier to maintain.
Run marked good and bad samples through the station before and after the change, and compare false rejects and escapes from production over the same number of shifts.
