Vision Software Ensures Perfect Code Reading on STADA Arzneimittel’s Distribution Packages
The use of image-based technology is quickly expanding in logistics. It enables processes to be configured more efficiently and products to be traced seamlessly. Pharmaceutical company STADA Arzneimittel AG, a specialist in the production of generic and OTC drugs, shows how modern image-based technology can optimise materials management.
In Europe, consumers understand that their pharmacy either has medication in stock or can get it from a pharmacy wholesaler within a few hours, although the technical expense behind this is enormous. STADA Arzneimittel, located in Germany, has over 4,100 products — including Grippostad, Mobilat and Paracetamol — at its approx. 6,000 m2 distribution and service centre in Florstadt, ready for delivery. Up to 1,000,000 medication packages leave the logistics centre every day in up to 11,000 different packages. STADA uses modern image-based technology to ensure that all cartons safely reach their destination. A camera portal, implemented by Weber System Technology, reads 1-D barcodes quickly and reliably with VisionPro vision software from Cognex.
Cartons assigned to customer order through print and apply app
STADA is working with commissioning waves for the highest degree of logistics efficiency. A varying number of cartons, based on order volume, moves over the approximately two kilometre long conveyor belt of the distribution and service centre. Each carton is first assigned to the relevant customer order through a process coined ‘marriage’, also known as a print and apply application. This occurs after its passing through the camera portal. The barcode of the incoming carton is read and linked to the customer order in SAP, and a labelling machine attaches the job code as an additional adhesive ticket for further processing.
Increased labelling efficiency with image-based technology
The greatest difficulties in logistics are often experienced with the labels. A label can be attached wrongly, may be damaged, have a defective printed image or may be missing altogether. STADA had previously used a laser scanner and up to 15% of the overall carton count was unreadable, which led to additional expense in manual re-processing and could lead to wrong products being shipped.
STADA’s demand for quality and efficiency led to a switch from laser to vision technology. Using image-based technology, the number of erroneous reads was reduced to under four percent within the shortest period of time — a significant increase in efficiency that reduced costs.
All sides of cartons inspected
The vision portal created by Weber System Technology contained five cameras to read the barcodes on the incoming packets. Two cameras inspect the long sides of the cartons on the same level as the conveyor belt; two additional cameras examine the front and back sides in the direction of movement 45 degrees from vertical; and the fifth camera looks down on the top nearly vertically.
Powerful vision technology from Cognex decodes the barcodes and transmits the data to the print and apply machine. The vision system is intelligent enough to ignore non-critical changes in the look of the code and to concentrate on the critical characteristics. Cognex software algorithms are powerful enough to be able to read barcodes that are damaged, highly reflective and omni-directional in only 400 milliseconds.
The outcome
The camera portal offers STADA not only increased efficiency through the significantly improved barcode reading process but also performance feedback if no reads occur. Image-based technology takes pictures of the barcode to read it, so if no reads occur, STADA can go back and review why and quickly alleviate any process errors.
Cognex UK Ltd, +44 1327 856040, www.cognex.com.