Ensuring Error-Free FMCG Manufacturing with Digital Defect Detection Systems

10.05.21 06:54 AM By Ekta

As an FMCG manufacturer, what comes to your mind when you think about a defect detection system? Are you visualizing several employees detecting defects on the production line? How reliable do you think manual inspection is? Manual inspection can be inaccurate and error-prone. Even the most experienced defect detector can miss or misidentify the accuracy of the products.

Apart from the accuracy and consistency, what about safety? Do the human inspectors wear masks and gloves at all times? How do you ensure they don’t remove their safety gears while you aren’t looking? These and several other risks are prevalent if you choose manual inspection in your factory.

Automated defect detection

Manual inspection has been used for a very long period but with digital innovation, it is time to change now. A machine vision defect detection system requires low or no human intervention and provides accurate and seamless results. Such systems are driven by artificial intelligence (AI) and are capable of identifying minute details and even the smallest errors like dents, contamination, scratches, dust particles, and many more.

Manual defect detection increases the possibility of missing small errors. Additionally, it is a labour-intensive and more expensive task. Manual inspection leaves lesser free floor space for the personnel and there is a risk of people constantly bumping into one another, which can result in petty arguments.

Human inspectors may be unable to detect minor errors like slight colour variations as they are constantly looking at the same things for an extended period. People can pay attention at a particular thing for a specific period, after which they require a break for better attention. Automated inspection systems do not have these limitations, as these are digitally influenced, ensuring accurate monitoring with the least human intervention.

Types of defects that can be identified by machine vision systems

High-end line-scan cameras driven by intelligent software and AI enable accurate and faster defect detection. Some of the defects that are easily identifiable with automated systems include:

Packaging and labelling

Accuracy of the labels is checked to ensure these adhere to the quality norms. Misprinted labels, missing labels, torn or unglued labels, and other such defects are identified. Each item is then categorized as OK or NG, which ensures defective products aren’t missed and shipped to the end users.

Dimensional quality

Automated systems for defect detection in manufacturing ensure standardized dimensions of the packages, which can be of various types like bottles, packets, boxes, bags, and more. Any deviation from the predetermined dimensions is immediately brought to attention and the product is not allowed to pass through further on the production line.

Printing accuracy

Correctly printed labels are an important aspect of fast-moving consumer products, any undetected variation may have severe consequences. The latest technology trends in FMCG industry like automated defect detection systems scan every label for accuracy, ensuring no defective product is shipped to the consumers.

Color Monitoring

A high-end vision detection system inspects the packaging to ensure it has the right spectrum of colours. Any deviation from the predefined parameters sends an immediate alert and is classified in the NG category.

Benefits of 
Automated Defect Detection 

Operational Efficiency

FMCG manufacturing must adhere to the highest quality standards to ensure brand reputation and consumer loyalty. An automated defect detection system checks every item for complete accuracy, which improves the operational efficiency. Any defect is detected in a timely manner, which reduces waste of raw materials and other resources. Additionally, returns are almost eliminated, which decreases shipping costs while protecting brand reputation. All these improve the operational efficiency and profitability for FMCG manufacturers.

Complete Accuracy & Faster Processing

Automated systems accurately detect even the smallest variations from the predetermined standards. Moreover, these systems are driven by AI, which constantly learn from patterns to identify OK and NG products. Any color variation, dents, torn packaging, misprinted labels, and other such defects are immediately identified with almost 100% accuracy and speed. Human inspection is prone to fatigue and monotony, which is eliminated in an automated system.

No human Interference

Automated machine vision systems require low or no human interference. These are driven by AI, which reduces personnel requirements. Employees can therefore focus on more fulfilling tasks, which not only increases job satisfaction but drive improved efficiency for the manufacturers. Companies can assign their personnel to more important jobs and eliminate any labour gap, which further improves efficiency and profits for the business.

Manual inspection is neither economical nor practical. Automated vision systems offer greater accuracy, speed, and reduce wastage and costs. FMCG production is massive and human inspectors may miss minor defects. Overcoming this limitation with digital defect detection system can ensure error-free manufacturing for FMCG companies.

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