Overview
Nestlé is one of the world’s leading food and beverage companies, with Maggi being one of its most popular brands in India. At its Tahliwal facility, Nestlé produces Maggi multipacks containing four tastemaker sachets (two in each layer).
As consumer demand grew, Nestlé faced rising complaints of missing or partial sachets—a challenge that traditional manual inspection could not solve at scale. With each line running 150 packs per minute, ensuring complete sachet presence was critical to maintain quality and brand trust.
Opportunity
Manual checks and traditional systems were insufficient for Nestle's high-speed Maggi multipack lines :
- Four sachets per multipack, stacked in two layers, were difficult to verify reliably.
- Folding or misplacement of sachets often went undetected.
- Even a small error translated into consumer complaints, product returns, and reputational risk.
- High throughput made 100% manual inspection impossible.
JIDOKA's Approach
- Vision-Based AI Inspection: Jidoka deployed a dual-station inspection system to verify every sachet in the multipack.
- Each Maggi multipack must contain four tastemaker sachets, placed in two layers.The challenge: you can’t check both layers at the same time — the top sachets hide the bottom ones.That’s why Jidoka used two inspection stations:
- Station 1: Checked the bottom layer (2 sachets).
- Station 2: Checked the top layer (2 sachets).
- Together, these two stations gave complete visibility of all four sachets and ensured none were missing.
- Each Maggi multipack must contain four tastemaker sachets, placed in two layers.The challenge: you can’t check both layers at the same time — the top sachets hide the bottom ones.That’s why Jidoka used two inspection stations:
- Defect Identification & Classification
- Detected and flagged missing sachets (plain or branded).
- Identified sachets that were folded, misplaced, or mis-cut.
- Maintained consistent accuracy even under challenging visibility and imaging conditions.
- Seamless Integration
- Fully integrated with Nestlé’s production line, connecting sachet detectors, check-weighers, sensors, dispensers, and rejection units.
- Automated rejection at line speed (150 packs per minute) enabled real-time quality control without slowing production.
- Scalability
- Designed to handle different multipack configurations and adapt to future packaging variations.
We needed a robust solution that could detect every sachet in real time, maintain our production speeds, and ensure zero consumer complaints.
– Packaging QA Manager, Nestlé India
Big Wins for Nestle
By deploying JIDOKA's AI-powered inspection Nestle achieved:
100% Detection Accuracy
Every sachet and crimp reliably verified.
0% False Rejection Rate (FRR)
Eliminated unnecessary rejections and line inefficiency.
Zero Consumer Complaints
Complete elimination of taste maker missing complaints.
2% Productivity Improvement
Eliminated frequent line stoppages, improving throughput.
Conclusion
With Jidoka’s vision AI system, Nestlé eliminated packaging errors in Maggi multipacks, protected brand trust, and ensured consistent consumer satisfaction. The transformation reduced complaints to zero, improved productivity by 2%, and set a new benchmark in packaging inspection reliability.
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