How Shriji Enhanced Pharma Bottle Cap Quality with Jidoka’s AI-Powered Smart Inspection

Using Jidoka’s AiI Visual Inspection Systems, Shriji automated defect detection for bottle caps on its wad assembly line—achieving real-time inspection speeds of 800+ parts per minute, reducing scrap , rework costs by over $10,000 annually.

How Shriji Enhanced Pharma Bottle Cap Quality with Jidoka’s AI-Powered Smart Inspection

Industry

Pharma Packaging / Plastic Manufacturing

Result 1

10+ defect types detected in under 0.1 seconds per part

Deployments

KOMPASS AI

Result 2

10% reduction in recurring defect occurrences

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.

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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.

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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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