EPIC designed the system around three core principles:
- Modular physical architecture
- Operator-focused usability
- Standardized controls and panel design
Modular Physical Design
The system was engineered as a multi-station modular platform capable of supporting several inspection points while maintaining a consistent architecture throughout the line.
Each station was designed with:
- Standardized lighting and camera configurations
- Enclosed inspection environments to eliminate ambient light variability
- Consistent mounting and mechanical layouts
- Repeatable hardware configurations across all stations
This modular approach simplified deployment, maintenance, and future scalability while ensuring inspection consistency across the system. The physical design also allowed EPIC to integrate directly into customer’s existing conveyors and sortation equipment without requiring a complete mechanical replacement.
HMI & Operator Interface Design
Because operators would interact with the system throughout production, EPIC focused heavily on usability and workflow simplicity.
The HMI was designed to:
- Provide clear real-time system status and inspection feedback
- Allow operators to quickly identify rejects or process issues
- Simplify SKU onboarding and changeovers
- Minimize training requirements for line personnel
One of the most critical features was rapid SKU training. Operators can:
- Scan a barcode to initiate a new product setup
- Run sample labels through the inspection station
- Train the system on new labels in under one minute
This streamlined workflow allows production teams to respond quickly to changing schedules and new products without requiring engineering support.
The interface also supports:
- Pass/fail visualization
- Reject notifications
- Product tracking visibility
- Simplified troubleshooting workflows
Rather than requiring dedicated vision specialists, the system was designed for everyday production operators.
Standardized Panel & Controls Design
EPIC also engineered a highly organized controls and panel architecture designed for maintainability and long-term reliability.
The panel design emphasized:
- Clean wiring and labeled components
- Standardized hardware across stations
- Logical organization for easier troubleshooting
- Simplified spare parts management
Component selection was intentionally standardized so maintenance teams could:
- Use common replacement parts across stations
- Reduce spare inventory complexity
- Improve long-term serviceability
The controls architecture also enabled:
- Centralized communication between inspection stations
- Integration with existing sortation controls
- Scalable expansion for future lines or stations
Because the system was built in-house, EPIC maintained flexibility throughout the design and implementation process, allowing updates and modifications without the delays often associated with outsourced panel shops.
