How Avon Seals Achieved High-Speed Dual-Face Seal Inspection with Jidoka

Using Jidoka’s AI-driven Eagle-Eye vision inspection system, Avon Seals automated quality checks for carbon and ceramic seals across 28+ variants — boosting defect detection by 40% and enabling 120 PPM dual-face inspection with full traceability.

How Avon Seals Achieved High-Speed Dual-Face Seal Inspection with Jidoka

Industry

General Manufacturing

Result 1

>99% Defect detection sensitivity

Deployments

Kompass (AI) enables Tigris

Result 2

Resource cost savings with automated sorting & traceability

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.

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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

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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.

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120 Parts Per Minute Throughput

High-speed dual-face inspection fully aligned with production scale and takt-time demands.

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28 Variants on One System

A unified hardware setup enables seamless variant switching with zero changeover downtime

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>90%Reduction in Operator Mundane Workload

Automated inspection eliminates fatigue-driven errors while boosting productivity and morale.

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Partnering with Jidoka to automate the inspection of our carbon and ceramic seal face components has elevated ourquality control standards to a level that manual inspection simply could not achieve.

What impressed us most was the team’s technical grit. Their ability to deep-dive into complex defect behaviours, understand thenuances of lapping marks, chipping variations, and shadow artifacts, and still engineer a system that performs with commendable accuracy on components that are inherently challenging to inspect.

Despite several real-world complications typical ofcarbon and ceramic surfaces, the Jidoka team responded with exceptional clarityand persistence. Every time we raised a technical concern, they analysed itthoroughly, refined the model, and ensured the system became sharper and morereliable.

The fact that the machine consistently rejectsdoubtful pieces rather than risking a false acceptance speaks volumes about itsrobustness and the engineering behind it.

They never hesitated to revisit assumptions, rework logic, or pushthe limits to meet our quality expectations.

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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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