Lens Packaging Inspection
100% automated inspection
Zero missing or wrong parts
Overview
Appasamy required a reliable smart visual inspection solution capable of inspecting multiple ophthalmic lens packaging variants across different inspection surfaces and quality parameters.
The application covered 4 major product variants and 8 lens shapes, requiring inspection of lens presence, code and label verification, QR-based serial number consistency, foreign particle detection, packaging integrity and component presence. Jidoka implemented an AI-powered inspection architecture using industrial cameras, indexed inspection stations, actuator mechanisms and the Kompass AI inspection platform.
Opportunity
The multi-variant lens inspection application required comprehensive automated inspection across different surfaces and packaging configurations:
- Multiple product variants with 8 different lens shapes required a flexible inspection architecture.
- Critical features such as lens presence, EO/CE codes, labels, QR codes, and serial number consistency needed to be verified automatically.
- Foreign particles as small as above 0.2mm needed to be detected on defined transparent surfaces.
- Pre-loaded lens packages required inspection of the top, bottom and four side faces.
- Additional packaging defects including missing components needed to be identified.
- Inspection requirements varied by product type, with cycle times ranging from 5 to 10 seconds per part.
Jidoka's Approach
Multi-Station AI Vision Inspection
Jidoka implemented a multi-station inspection architecture using industrial cameras, indexed rotation, and actuator mechanisms to provide comprehensive inspection across the defined surfaces.
High-Resolution Top & Side Inspection
The top and side inspection station uses multiple cameras mounted on a 2-axisactuator system to capture high-resolution images of the lens package. Infrared cameras support lens presence and foreign-particle inspection, while acolour camera verifies colour-based features.
Label, Code & QR Verification
The system verifies the presence and colour of EO/CE codes, checks top and side labels, and performs QR-code comparison for serial number consistency. For pre-loaded lens variants, the solution also supports bottom-label inspection and image storage based on QR information.
Multi-Surface Inspection
For pre-loaded lens variants, an indexed inspection arrangement enables sequential inspection of the top, four side faces, and bottom face. A dedicated bottom-label inspection station uses a camera positioned beneath a transparent inspection surface for label verification.
AI-Based Decision & Automated Sorting
Captured images are processed on an on-premise industrial edgecomputer running Jidoka's Kompass deep-learning AI platform. Thesystem classifies each inspected part as OK or NG based on configuredinspection criteria. Post-inspection, a pneumatic ejection mechanismautomatically segregates the parts into designated OK and NG bins.