Overview
Shriji isa global leader in pharma-grade plasticpackaging solutions, manufacturing high-precision bottle caps thatdemand stringent visual quality standards. Each cap must be free from surfaceanomalies and assembly defects to ensure sealing integrity and pharmaceuticalcompliance.
However,with over 1 million bottle caps toinspect daily, manual or semi-automated inspection methods struggled tomaintain both throughput and consistency. Delayed defect feedback led tounnecessary rework and high rejection rates. Shriji needed a high-speed, reliable, and traceableinspection system capable of handling massive production volumes withoutslowing down the line.
Opportunity
Manual inspection and legacy systems couldn’t keep pace with Shriji’shigh-volume bottle cap production:
- Over 1 million caps produced dailymade 100% manual inspection impractical.
- Minute defects such as sealingdamage, contamination, or surface irregularities often went undetected.
- Delayed feedback on rejectionsled to higher scrap, rework, and wasted production time.
- Even a small batch of undetected defects could result in costly product rejections and customer dissatisfaction.
Jidoka's Approach
- High-Speed Single-Camera Inspection Architecture
A single high-resolution top cameracaptures both the top and innersurfaces of each bottle cap as they move on Shriji’s existing conveyorautomation line.
- EdgeAI–Enabled Defect Detection
Jidoka’s proprietary Kompassdeep-learning engine runs inference on captured images in less than 100 milliseconds,identifying and classifying defects in real time with high precision.
- Automated Decision and Ejection
The system delivers immediate OK/NG decisions, directly linked to an automatic pneumatic rejection mechanismthat removes defective caps from the line instantly—eliminating lag betweendetection and response.
- Smart Traceability and Alerts
Each inspection result is logged and visualized on a digital dashboard. Operator alerts notify of recurringdefect trends, enabling proactive maintenance and data-driven process improvement.
Big Wins
Major Outcomes for Shriji
800+ Parts/Minute
Achievedhigh-speed inspection without throughput loss.
$10K Annual Cost Savings
Reducedrework and scrap losses.
10% Reduction in Defect Occurrence
Continuousfeedback loop drives improvement.
ROI Achieved in 18 Months
Fastpayback through efficiency and quality gains.
With Jidoka’s AI-powered smart inspection system,Shriji successfully transformed its bottle cap quality assurance process. TheEdge AI solution delivered high-speed, real-time defect detection withunmatched consistency, traceability, and accuracy—reducing scrap, preventingdefect carryover, and strengthening overall manufacturing reliability. Thisdeployment marks a key milestone in Shriji’s journey toward fully automated, data-driven quality controlin pharma packaging.
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