Large-scale factories in Vietnam continue to face major operational challenges, including schedule delays, production conflicts, and reduced equipment efficiency caused by bottlenecks. At the core of these issues is information management: a disconnect between management and shop-floor operations, inaccurate data collection, and slow reporting.

Without real-time data, identifying root causes, addressing emerging issues, and making timely decisions become daunting challenges that ultimately hinder the overall competitiveness of the business. 

New Ocean Group’s Web Narrow – Flexo Label Printing Quality Inspection Solution was developed not only to correct minor printing defects, but also to address the root causes of these strategic challenges. It is not just a standalone device, but a smart data-driven solution that empowers senior leaders with a powerful tool to ensure quality, optimize processes, and comprehensively manage risks. 

I. The Hidden Cost Gaps of Traditional Printing Errors 

In the printing industry, especially in flexo printing, product defects are not only a technical issue but also a significant financial burden that silently erodes a company’s profitability. The costs of these defects can be divided into two categories: the more visible - Deadweight Loss, and the harder-to-quantify - Hidden Costs. 

Deadweight Costs from Waste and Reproduction 

Printing errors on flexo machines are inevitable. Common issues include ink spillage, filling-in of print elements, uneven ink layers, smudging, and poor ink transfer.  

When these errors occur, factories are forced to take costly corrective actions such as cleaning the printing plates, adjusting ink viscosity, or replacing components like anilox rollers. Each adjustment and reprint results in wasted printing materials, ink, and energy. Over time, these costs accumulate into a substantial figure that directly reduces the profit margin of every order. 

Hidden Costs and Uncertainty in Management 

Beyond material costs, manual visual inspection or other outdated methods generate a range of hidden costs that senior managers need to be aware of. 

• Risks from Labor and Downtime: Quality control heavily depends on workers’ skills and focus. This approach is time-consuming, costly, and highly prone to errors. Once a defect is detected, the production line may need to stop, causing significant downtime and reducing equipment efficiency. In many cases, defects are only discovered at the end of a shift or day, by which time a large volume of defective products has already been produced. 

• Helle Without an automated tracking and reporting system, managers cannot obtain accurate and timely data on production performance. Identifying the root cause of defects becomes difficult, disrupting planning and making order completion times unpredictable. This directly impacts the ability to meet orders with short lead times—an increasingly critical factor in modern manufacturing. 

Business Risks: Lessons from Pharmaceutical Industry 

Although roll packaging and label printing are often considered a simple process, errors can lead to catastrophic consequences—especially in highly sensitive industries such as pharmaceuticals. Statistics show that labeling mistakes or misprints on packaging are among the leading causes of product recalls. For example, a seemingly small error such as printing “500mg” as “50mg,” or an incorrect batch number, can pose serious risks to consumers and trigger large-scale recalls. 

For business leaders, this risk extends beyond financial losses to brand reputation and regulatory compliance. The costs of product recalls, fines, and loss of customer trust are enormous and can even threaten the survival of an entire company. An automated quality inspection solution not only helps reduce reprinting costs but also serves as a “shield” that protects businesses from these potential disasters. 

II. Strategic Vision: Quality Inspection Solution Powered by AI Technology 

Amid these challenges, New Ocean Group’s Web Narrow – Flexo Label Printing Quality Inspection Solution emerges as a strategic tool—transforming quality control from a mere operational cost into a lever for comprehensive optimization. Our system has already been exported to Bangladesh and several other countries.  

• Superior Accuracy with AI and High-Resolution Technology: The solution leverages artificial intelligence (AI) combined with high-resolution cameras (2K, 4K, 8K). This system not only automatically detects and classifies even the tiniest printing defects invisible to the human eye, but also completely eliminates reliance on workers’ skills and concentration. With this capability, it ensures up to 100% output quality, immediately reduces waste, and prevents unnecessary losses. 

• Optimize Performance with Unlimited Speed: With an inspection speed of up to 200m/min, New Ocean Group’s solution can operate in parallel with the printing speed of flexo machines. This is a critical factor for managers, as it removes the barrier of having to slow down production to ensure quality. The quality inspection system is seamlessly integrated into existing production workflows without creating a new bottleneck. 

• Maximize Existing Assets with Flexible Integration: Instead of requiring major investments in new machinery, New Ocean’s solution can be flexibly installed and integrated even with existing printing systems. This enables businesses to maximize returns on their current assets, minimize upfront investment costs, and shorten ROI timelines. This capability also reflects a deep understanding of manufacturers’ financial challenges, allowing them to embrace digital transformation step by step in an effective and sustainable way. 

III. Local Advantage: Differentiation that Builds Lasting Reliability 

As Vietnam’s automation market continues to grow with numerous domestic and international providers, choosing a local partner like New Ocean Group offers outstanding strategic advantages—not only in terms of cost but also in ensuring operational reliability. 

• 24/7 Technical Support with Local Expertise: One of New Ocean Group’s greatest advantages is its 24/7 local engineering support team. This directly addresses core challenges when working with international partners: language barriers, time zone differences, and slow response times. In a production line, every minute of downtime means financial loss. Having on-site experts who understand both the manufacturing processes and the local working culture ensures that issues are resolved quickly, minimizing downtime and maintaining system stability. 

• Customization and Strategic Partnership: The software solution is developed in-house by New Ocean. This provides a significant advantage in customizing the system to fit the unique production processes of each factory. In contrast, international providers often deliver pre-packaged solutions that are difficult to adapt to specific requirements.  

Moreover, New Ocean Group is a pioneer in digital manufacturing transformation with its DxFACTORY ecosystem. This means that by choosing our printing quality inspection solution, businesses are not simply purchasing a product—they are establishing a strategic partnership, ready to take the next steps in their automation and digital transformation journey. 

IV. The ROI Equation 

Investing in New Ocean Group’s solution is not merely an expense—it is a strategic investment that delivers clear and compelling returns, reflected through tangible figures and key business metrics. 

• Waste Reduction and Productivity Maximization: With 100% product inspection and real-time defect detection, the solution significantly reduces waste. This not only saves material costs but also boosts the overall productivity of the production line. 

• Labor Efficiency: By automating labor-intensive quality inspection processes, the solution frees up human resources for higher-value tasks. This reduces labor costs while improving overall workforce productivity. 

• Risk Management:: Preventing critical printing errors helps minimize the risk of product recalls, safeguard brand reputation, and avoid substantial legal and financial costs. 

• A Platform for Sustainable Growth: With intelligent data management, storage, statistical reporting, and reusable settings for similar products, the solution becomes a powerful management tool. Business leaders can analyze production data to identify opportunities for efficiency improvement and make decisions backed by real-world insights. 

Conclusion 

New Ocean Group’s Web Narrow – Flexo Label Printing Quality Inspection Solution is a strategic investment designed to address the core challenges faced by large-scale manufacturers in Vietnam. Powered by AI and intelligent data management, it not only optimizes performance and reduces hidden costs but also serves as a comprehensive risk management tool, protecting business value and brand reputation. 

The advantage of in-house software development combined with a 24/7 local engineering team provides peace of mind, reduces total cost of ownership, and fosters long-term partnerships. This is not just a technological advancement—it is a transformation in management mindset. To achieve sustainable growth and enhance competitiveness, manufacturers must not only produce faster, but also smarter. 

For more details on how the solution can be customized to your specific production needs—and to learn about successful projects that New Ocean Group has implemented both in Vietnam and globally—we warmly invite business leaders to get in touch with us directly. 

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CONTACT INFORMATION   

New Ocean Automation System Company Limited   

Website: New Ocean Automation System  

Hotline: 1900 0224   

Email: customercare@new-ocean.com.vn