Vision System Inspection Fail

Machine vision system has flagged a product as failing inspection. Product may have print defect, wrong label, missing component, or dimensional error.

Probable Causes (ranked)

• Actual product defect — print error, missing label, wrong color, dimensional issue
• Camera lens dirty — contaminant on lens causing false rejects
• Lighting changed — ambient light shift, bulb aging, or light fixture moved
• Vision recipe does not match current product — wrong inspection program selected
• Camera focus shifted — vibration or temperature change altered focal distance
• Product positioning inconsistent — conveyor speed variation or guide rail gap

Fix Steps

1. 1 Check the rejected product — verify if the defect is real or a false reject
2. 2 Clean camera lens with appropriate lens tissue and inspect lighting fixtures
3. 3 Verify the correct vision recipe/program is selected for the current product run
4. 4 Check lighting intensity and uniformity — replace aging bulbs or LEDs if dimmed
5. 5 If false rejects are increasing, recalibrate or re-teach the vision inspection
6. 6 Verify product positioning through the camera field of view — adjust guide rails if needed
7. 7 Check camera focus — use live image display to verify sharpness on product features
8. 8 Review reject history for patterns — same defect location may indicate upstream process issue

Suggested Replacement Parts

Parts matched to fault category: Vision Camera

Prices are estimates. Verify part numbers match your equipment before ordering.

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