Consumer Packaged Goods · Assembly & Final Pack

Label & Vision Inspection Integration

Extend print head life by 2.5× and recover 42,000 saleable units per month by eliminating false rejects.

+1.4 pts

First-Pass Yield

From 97.5% to 99.0% vision FPY, 1.5M fewer units reprocessed per month

−87%

False Rejects Eliminated

False reject rate from 1.2% to 0.15%, recovered 42,000 saleable units per month

+2.5×

Print Head Life

Predictive cleaning scheduling extended head life from 168 to 420 hours average between maintenance events

How Allie Works Here

From signal to action in real time.

Quality ControlProduction Optimization

The Quality Control agent maintains per-SKU vision pass/fail models updated with each production run, automatically tightening or relaxing inspection thresholds based on the print head age curve learned from Domino OPC-UA diagnostics data. When OCR read rate on date codes drops below 99.2%, the leading indicator for impending print head degradation, the agent schedules a head clean during the next micro-break rather than waiting for a hard fail. The Production Optimization agent analyzes the false reject pattern in real time and distinguishes mechanical misalignment rejects from true print defects, enabling targeted corrective action rather than blanket threshold relaxation.

Machines & Connectivity

OT-connected, protocol-native.

Domino A420 Inkjet Printer

Domino Printing Sciences

OPC-UA

High-resolution date, lot, and barcode printing on primary packages at line speed

Cognex In-Sight 2000 Vision System

Cognex

EtherNet/IP

100% print quality and label position inspection with configurable pass/fail logic per SKU

Panasonic FP-X0 PLC

Panasonic

Modbus TCP

Reject gate sequencing controller receiving fail signals from vision system with configurable delay compensation

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Vision First-Pass Yield	`INSP01.VIS.FPY`	%	96.8–98.2	99.4–99.8	Higher
OCR Read Rate on Date Code	`INSP01.OCR.RATE`	%	97.1	99.7	Higher
False Reject Rate	`INSP01.FALSE.REJ`	%	0.8–1.6	0.1–0.2	Lower
Print Head Maintenance Interval	`INSP01.PRNT.INT`	hours	168	420	Higher

Vision First-Pass YieldHigher

INSP01.VIS.FPY

Baseline: 96.8–98.2 %→ 99.4–99.8 %

OCR Read Rate on Date CodeHigher

INSP01.OCR.RATE

Baseline: 97.1 %→ 99.7 %

False Reject RateLower

INSP01.FALSE.REJ

Baseline: 0.8–1.6 %→ 0.1–0.2 %

Print Head Maintenance IntervalHigher

INSP01.PRNT.INT

Baseline: 168 hours→ 420 hours

In the Field

"a CPG contract manufacturer running 8 packaging lines with strict retail compliance requirements for date code legibility"

Deployed at a CPG contract manufacturer running 8 packaging lines with strict retail compliance requirements for date code legibility. The results above reflect production data from the 60–90 day period following full deployment.

+1.4 ptsfirst-pass yield

−87%false rejects eliminated

+2.5×print head life

Next Step

See what your lines are actually capable of.

A 30-minute operational assessment. We review your OT/IT setup, identify the highest-ROI deployment, and deliver a scoped pilot proposal.

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