Overview
Avon Seals Pvt. Ltd. is one of India’s largest manufacturers of mechanical seals for agricultural, domestic, and automotive water pumps. Their products support leading OEMs in India, Europe, and the USA — making consistent quality and reliability non-negotiable.
Manual dual-face inspection led to missed micro-defects, fatigue-driven inconsistency, and alack of traceability. As production demand grew, Avon Seals required a more reliable and scalable quality solution — prompting the shift to Jidoka’s automated inspection.
Opportunity
Scaling to 100% automated quality inspection required solving several challenges:
- Inspect top and bottom faces within a single continuous flow
- Support 28 product variants (color, diameter 20–40 mm, surface finish differences)
- Detect micro-defects as small as 0.3 mm
- Maintain 120 parts per minute throughput
Jidoka’s Approach
- Dual-Face AI Vision Inspection
- Two synchronized cameras inspect the seal’s top and bottom faces.
- Station-1 captures top-face images using custom precision illumination, while Station-2 inspects the bottom face after anon-stop automated flipping mechanism rotates each seal in motion.
- High-Accuracy Defect Detection & Classification
- Jidoka’s deep-learning engine identifies micro-defects such as chipping, short fills, cracks, surface lines, and lapping marks with >99% sensitivity and >95% specificity.
- Each part is classified as OK / NG / Rework /Manual-Verification based on severity and rules.
- Automated Sorting & Seamless Line Integration
- Inspection verdicts are sent instantly to the PLC, triggering auto pneumatic ejection for NG and reworkable pieces — while OK parts continue downstream for packing.
- The system integrates easily into existing lines without interrupting production flow.
- Scalability & Smart Analytics
- A single setup supports 28 product variants and up to 120 parts per minute, enabling future expansion with zero hardware changes.
- All inspection data is logged with defect images and production metrics, powering live dashboards, traceability, and continuous quality improvement.
Big Wins
By deploying Jidoka’s Kompass and Tigris, Avon Seals achieved:
40% Better Defect Detection
Consistently catches micro-defects like chipping and cracks that previously escaped manual inspection.
120 Parts Per Minute Throughput
High-speed dual-face inspection fully aligned with production scale and takt-time demands.
28 Variants on One System
A unified hardware setup enables seamless variant switching with zero changeover downtime
>90%Reduction in Operator Mundane Workload
Automated inspection eliminates fatigue-driven errors while boosting productivity and morale.
With Jidoka’s Kompass-powered dual-station system, Avon Seals achieved high-speed, highly accurate inspection for both faces of carbon and ceramic seals —eliminating manual dependency and enabling precise defect categorization with traceability. This transformation ensures consistent world-class quality for leading global pump manufacturers while unlocking future automation possibilities across production lines.
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