Design Qualification of Domino Printing Machine

OBJECTIVE for Design Qualification of Domino Printing Machine

To determine that the Design Qualification of Domino Printing Machine perform as intended by repeatedly running the system on its intended schedules and recording all relevant information and data. Results must demonstrate that Design consistently meets per-determined specifications under normal condition, and where appropriate the worst-case situations.

TABLE OF CONTENT

Description

Objective

Table of contents

Scope

Pre-Approval of Documents

Responsibility (client and manufacturer)

Scope of supply

Brief process description

Technical specifications

Safety features and alarms

Technical specifications of the bought-out components

Post approval of Documents

List of Abbreviations

SCOPE

The scope of this qualification document is to perform the Design qualification to verify the installed components as described in DQ.

PRE APPROVAL OF DOCUMENTS for Design Qualification of Domino Printing Machine

Prepared by

Designation	Name	Date	Signature
Executive/Officer Engineering

Reviewed By

Designation	Name	Date	Signature
Head Engineering
Head Production

Approved by

Designation	Name	Date	Signature
Head QA

RESPONSIBILITY:

Client:

To provide the Scope of supply.
To give final approval to drawing and technical data sheet.

Manufacturer:

To design, engineer and provide complete technical details of the Equipment.
To confirm safe delivery of the equipment to the user site.
To ensure that no un-authorized and/or unrecorded design modifications shall take place. If at any point of time, any change is desired by mutually agreed design, change control procedure shall be followed and documented.

SCOPE OF SUPPLY:

Design of the machine shall meet the Scope of Supply finalized with the Customer.
To define the customer’s & the manufacturer’s responsibilities.
To provide the brief process description of Carton Printing Machine.
To provide the technical Specifications of the Carton Printing Machine.
To provide the information on bought out components.

BRIEF PROCESS DESCRIPTION for Design Qualification of Domino Printing Machine:

Thermal ink jet printers are designed for use on moving production lines that require printing of Fixed and variable text, 1D and 2D codes, and graphics on porous and non-porous substrates. This range of printers can print at speeds of up to 300 m/min at 60 dpi to 30 m/min at 600 dpi, at a print height between12.7 mm and 50.8 mm and a resolution of up to 600 dpi. The range can run up to 2 or 4 print heads on maximum 2 or 4 different groups from a single controller. A print group can be adjacent to the product or on as separate production line depending upon encoder ports available in different controllers, enabling a single controller to code on up to 2 or 4 lines. Separate print heads can be stitched together to allow a wider print of up to 50.4mm. A replaceable cartridge contains the print engine (nozzle plate) and the ink supply (42ml).
Two types of ink are available: water-based (porous substrates) and ethanol- based (multi-substrates). The coder can be connected to a product sensor that will trigger the start of a complete marking sequence for a label.
All models are controlled by the application software package and the proprietary operating system, housed in the internal SD card in the controller. All labels and configurable settings are saved on the SD Card. The printer includes a slot that will accept a removable USB memory stick. The card allows system up grading, backup and restore, and the uploading and downloading of data.
The following groups of functions are provided:

1. Label view

2. Ink

3. Construction and storage of labels

4. Machine configuration, diagnostic, data transfer and service functions

5. Access control

6. Reporting of exception conditions.

7. Printing of labels

CONTROLLERS

Gx-IC10 Controller

The Gx-IC10 Controller features a 10″ touch screen and an IP64 rating. Setup, configuration, and label creation/editing are done directly on the controller.

Gx-OEM Controller

The Gx-OEM Controller is designed to be integrated into machinery and fitted into control cabinets. It is designed to be integrated with OEM production line systems.
The controller’s settings and label creator/editor are accessed using the web browser from any Ethernet- connected PC.

Interfaces

Quick step Interface Home Screen

	Setting Name	Explanation
A	Information Bar	Displays printer information.
B	Start	Start printing.
C	Stop	Stop printing.
D	Status Tab	Displays printer status and alerts. If more than one alert is present, the highest priority alert is displayed. If an alert is displayed, select the Status Tab to show more information and to clear the alert.
E	Assign Label (Print Group 1)	Select and assign a label to print group 1.
F	Assign Label	Select and assign a label to print group 2.
G	Assign Label (Print Group 3)	Select and assign a label to print group 3.
H	Assign Label (Print Group 4)	Select and assign a label to print group 4.
I	Home	Press the Home Button at any time to return to this Home
J	Printer Name	Displays the name of the printer that the user interface is connected to The name can be changed by selecting Home > Setup > System information and changing the Printer name setting
K	Label Manager	Open the label manager to create new labels, edit labels, preview labels and send labels to print
L	Number of labels	Displays the number of different labels that are selected for printing
M	Ink settings	Open the Ink settings menu.
N	Setup	Open the Setup screen.
O	Date/Time	Displays the system date/time.
P	Lock	Log the user out from the printer. Change the user’s password. Lock the screen to prevent accidental changes.

Setup Screen

The Setup screen contains advanced printer settings, diagnostic tools and wizards. This screen is accessed by selecting Setup on the Home screen.

The illustration below shows the Setup screen.

ACCESS CONTROL

User access to the system is controlled, via the ‘User Level’ menu, by a user type system.

The controller is delivered with 4 accounts, each with its own set of access permissions.

They are as follows:

UserType	Permissions
User	Start/Stop Printing. View information screens. Preview labels in the controllers label store. View printer diagnostics/statistics screen. Select the user interface language. View system information. View ink settings.
Settings	Same as “User” plus: Select labels for printing. Adjust LCD backlight brightness. Manually purge the print head.
Service	Same as “Settings” plus: Create and save new labels. Edit labels. Edit production line setup. Edit global print settings. Edit or defaults. View diagnostic logs. Edit alert configuration. Edit date and time. Create label and service backups. View file manager.
Administrator	Administrator access to all printer settings.

The user type “User” is the default user when the system is powered on and does not require a password; the “Settings”, “Service”& Administrator user types each have a password that must be entered in order to log on

POWER ON SEQUENCING

The printer adopts the Printer On state when mains ON/OFF switch is turned On and after home screen appears the Start button located at center on the home screen is pressed for switching ON printing.
The printer will start in the view of home screen and will show the last loaded label when the machine was turned off.
The printer adopts the Power Off state when Stop button located at center of home screen is pressed and electrical power is turned off.
Note: In Gx-OEM Printer 24 Volt DC supply need to be enable/Disable to perform above mentioned Power ON and OFF sequence.

MANUAL FUNCTION – LABEL CONSTRUCTION

Label menu

The new labels or modifications of existing labels are temporary (they will be lost when the printer’s power is turned off) –until they are saved and stored in the Label Library.

The label contents

A label is built from blank space and one or more of the following fields:

Fixed text:

Including special characters (e.g. language characters, currency symbols, etc)

Date/time:

A range of format options

Counter:

Used to serialize a product. Counters may be configured according to requirements. Please refer to the Gx-Series Product manual; Part No. EPT053091 for further details.

Graphics/Logo:

JPEG, PNG & Bitmap (bmp) format are supported.

Shift Code:

The ‘Shift Code’ table need to be created first in label Shift code before inserting same into Label

Barcode:

1D – Fixed length barcodes including:

Variable length barcodes include Data matrix

Data matrix GS1-128

Variable Text:

Enables updating of data field inside a label without editing the content of the label – can be used to send label content from a PC. A field is added and formatted, in the Data Entry screen, by pressing keys on the Web based UI screen keyboard:

Pressing the ‘Right Check arrow’ Function key confirms the entry and returns the user to the label display screen.

The appearance of the label

The appearance of individual components may be modified in the Data Entry screen.

The parameter available for modification are dependent on the field type, but may include

Font
Font size
Font style (Complete Block,
Horizontal and Vertical position
Rotation
Inter character Gap
Bold
Alignment
Negative printing
Chimney-Tower print
Visible print
Invert
Invert Black/White

Saving the label

The label can be saved from the Floppy button available in label editor menu. The label will be saved in the Label Library.

Making the label available for printing

Once saved, the label is made available for printing by loading it on a print head group. This can be performed from the Label manager tab available on home screen.

MANUAL FUNCTION – USING THE LABEL MANAGER

Label menu

The label/label manager contains a permanent “library” of labels indexed by label “names” and its functions are designed to maintain the library and make its contents available for printing.

The store’s contents are displayed as a scrolling list of label names. The keys on label allows an individual label to be selected from the store.

Functions in label manager provides the following functions on a selected label:

‘Print’ a label on to a print head

‘Edit’ a label for any changes to be done

‘Preview’ a label before printing

Create a new Label

MANUAL FUNCTION – PRINTING OF LABELS

Print menu

A label must first be loaded on a print head group that print head group can then be activated for printing.

One, more or all print head groups can be activated for printing by pressing Start button on Home Screen of user interface screen.

MANUALFUNCTION-LABELARCHIVEANDRECOVERY

This function is available when the either the Service & Administrator password has been entered. It is accessed via the Home | Setup | File manager menu.

The file manager is used to import, export, view, organize and rename labels, images, font files, and other file types. The file manager can also copy files from a USB memory device.

The function allows the operator to copy sets of label or logos between the printer’s internal memory and an external Flash Card memory.

Export labels: the selected label or all labels currently present on the internal memory can be copied to the external card. The operation cannot be interrupted once started and its success or otherwise is reported on the screen.
Import labels: the selected label or all labels currently present on the external card can be copied to the internal memory.
Export logos: the selected logo or all logos currently present on the internal memory can be copied to the external card. The operation cannot be interrupted once started andits successor otherwise is reported on the screen.
Import logos: the selected logo or all logos currently present on the external card can be copied to the internal memory.

MANUAL FUNCTION – SETUP

Below functions is available when the either the Service & Administrator password has been entered.

It is accessed via the Home | Setup | menu.

Production line setup

Line movement used for encoder setup

Print Group setup used for defining installation of print head

Install print head groups

set print head group parameters

Setup of Print trigger signal

Setup of different Inputs and Outputs

Setup of Label selection using external mean.

Global Print Settings

Counters settings

Variable test settings

Defaults settings for label can be set for new label

Editor default

Element Property Default- Text & image element’s default property can be set

Content Property default- Clock, script, counter, variable content

Printer Diagnostics

Various statistics of printer status

Statistics of label & Print counter

Regional

Language and Keyboard settings

Date & Time setting

Ink settings

All ink related operation.

MANUALFUNCTION–LABELEditor

This menu function allows:

Edit, copy, delete, move an element
Saving of label
Zoom function for selected field

MANUAL FUNCTION – ALARMS

The user is alerted to an alarm condition when the red Alarm button flashes on home screen.

Please refer to the Gx-Series Product manual; Part No. EPT053091 for further details on full list of Alarm messages.

A clear alarm messages function available on home screen status tab. A history of alarms can be viewed.

The basic construction of the machine consists of:

Standard stainless steel 316 with matt finish for contact parts.
Standard stainless steel 304with matt finish for non-contact parts.

TECHNICAL SPECIFICATION for Design Qualification of Domino Printing Machine:

Particulars	Specifications
Name of Equipment/system	ThermalInkJet Printer
Equipment Make / Model	Domino Gx350i TIJ Printer or equivalent
Purpose of equipment	Thermal Ink Jet Printer is designed to use printing & to put bar code onBlisters with product information.
Capacity/Coding Speed	150 ppm
Product / Material	Laminated & Non-Laminated Mono Carton
Environment / Temperature	Ambient
Coding purpose	Batch Coding
Coding position	From Above
Position/Installation	On Stacker Application
No of lines	4 Lines Message
Shaft Encoder	Yes
Scratch resistance	20 Times Finger Rubs
Coding area size (HxB)	11 mm x 35 mm
Character height/width	2 mm / 2 mm
Process Requirement (s)	Four print head with premium black cartridge required. Print features :Left/Right, Upside- down. Print Head size should be12.7mm suitable for all standard application. It should have driven up to four print heads independently or together. User Interface: Color touch screen with WYSIWYG image display. Temperature control and portable ink level tracking.Selectableinktypesettinghelpsensuretheright ink is being used.OptionalUSBscannerformessage selection.Intuitive,graphicaluserinterfacewitheasyto learn icon-based controls.Basicalphanumericcodestocomplexbarcodes and graphics, if required 2 D codingWiderangeofbarcodesincludingData-Matrix and stacked symbologiesSystemshouldshowprintstatusoncartridges (e.g. Cartridges needs to change) Process Control: Shouldhaveuserlevelrights protectionShouldhavesimpleuserinterface operationIt should have user friendly operating functions/ProcessIn case of defects in the material the system shouldgiveaudio,alarmwhichisdisplayedinthe display unit Functionality: Advancedcommunications protocolfor remote operation and high speed.Solidstateelectronicswithnomovingparts.Selectableinktypesettinghelpsensurethe right ink is being used
Electrical connection	100-240 V AC. 50-60 Hz, 3.5 A with UPS

SAFETY FEATURE & ALARM

Safety feature	Function
Emergency Stop	Push button with indicator
Power Failure/Recovery	Automatic recovery after resume the power supply
Electrical Protection (Flame Proof / Non-Flame Proof)	Electrical protection/non-flame proof
Alarms & warnings	Should be displayed on HMI.

TECHNICAL SPECIFICATION for Design Qualification of Domino Printing Machine

Particulars	Specifications
Control panel-MOC	Touch screen (10”), ss covering, with moveable system.
Indicator(s)	Printer status indicators with buzzer.
Alarms and warnings	Display should indicate on the HMI.
MMI / HIM AND PLC details	PLC operated with printing (optional), USB mode, rs232 port.
Data storage capacity	Memory of min 200 – recipes
Password Protection	4 level password protection Operator level Supervisor level Maintenance level Admin level
Manual Controls	Applicable
X head plate kit	1 head, one way
Printhead cable	3m assay
Encoder kit	3m, 200mm circumference wheel
GX 350I & OEM	Remote mounted photocell
Domino ink cartridge	Solvent based 42ml black BK117 g-series (pack of 1) lot number: TIJ-BK1175_ AD000566Black solvent based TIJINK, g/gx-series cartridge (pack of 1), general-purpose number: TIJ-BK119-5_AA000094
Standard adjustment kit	Applicable
Side mounted bracket	Applicable
GX-series user guide	Applicable
Grounding cable kit	Applicable
Documents/Drawings	Material of construction Certificate(MOC)of Contact Parts/Non-contact parts Calibration Certificates traceable to NIST standard Performance Test Certificates Operation and Maintenance Manual Spare Parts List MOC certificates GA Drawing Electrical

POST APPROVAL OF DOCUMENTS