Cleared inspection backlogs for a high-speed FMCG bottling line
We delivered AI-powered label, barcode, and regulatory text inspection with automated rejects and batch-wise MES analytics.
FMCG manufacturing (bottled goods) Case Study
THE CHALLENGE
What was holding them back
Operational pain
Manual label inspections at 300 bottles/min caused missed defects and bottlenecks.
Business risk
Incorrect barcode/text/layout risked recalls, penalties, and brand damage.
Why tools failed
Human checks could not scale to line speed, creating inspection backlogs.
CLIENT SNAPSHOT
About the client
THE SOLUTION
Our FMCG manufacturing (bottled goods) Solution
High-Speed Label + Barcode Verification
- Verified barcode readability, label presence, and placement at full line speed.
- Flagged text, layout, and print-quality deviations in real time.
Automated Regulatory Text Checks
- Detected missing or incorrect statutory statements before products left the line.
- Standardized checks across batches to reduce compliance variability.
IIoT-Driven Reject Handling
- Integrated vision outcomes with reject mechanisms for instant diversion.
- Reduced manual intervention through automated fault classification signals.
MES Batch-Wise Analytics
- Logged inspection results to MES for traceability by batch and timestamp.
- Enabled batch dashboards for quality trends, defect types, and hotspots.
Operator Workflow, Alerts, and Controls
- Provided live alerts for recurring defects to stop repeat errors quickly.
- Role-based views for QA, production, and supervisors to act faster.
THE IMPACT
Measurable Results
Accuracy: 99%+ defects detected across label checks
Compliance
regulatory text verification achieved
Throughput: 300/min sustained inspection without slowdowns
Backlog: 0 inspection queue during peak runs
Productivity
fewer manual QC hours (standard)
Traceability
batch audit trail in MES
weeks Time-to-value
to production rollout (standard)
TECH STACK
