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

Using Jidoka’s AiI Visual Inspection Systems, Shriji Enhanced Pharma 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.

OVERVIEW

Shriji Enhanced Pharma is a global leader in pharma-grade plastic packaging solutions, manufacturing high-precision bottle caps that demand
stringent visual quality standards. Each cap must be free from surface anomalies and assembly defects to ensure sealing
integrity and pharmaceutical compliance.

However, with over 1 million bottle caps to inspect daily, manual or semi-automated inspection methods struggled to maintain both throughput
and consistency. Delayed defect feedback led to unnecessary rework and high rejection rates. Shriji needed a high-speed, reliable, and traceable
inspection system capable of handling massive production volumes without slowing down the line.‍

THE OPPORTUNITY

Manual inspection and legacy systems couldn’t keep pace with Shriji’s high-volume bottle cap production:

    • Over 1 million caps produced dailymade 100% manual inspection impractical.

    • Minute defects such as sealing damage, contamination, or surface irregularities often went undetected.

    • Delayed feedback on rejections led 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 camera captures both the top and inner surfaces of each bottle cap as they move on Shriji’s existing conveyor automation 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 mechanism that removes defective caps from the line instantly eliminating lag between detection and response.
  • Smart Traceability and Alerts
    Each inspection result is logged and visualized on a digital dashboard. Operator alerts notify of recurring defect trends, enabling proactive maintenance and data-driven process improvement.

Industry

Pharma Packaging / Plastic Manufacturing

Deployments

KOMPASS AI

Results 1

10+ defect types detected in under 0.1 seconds per part

Results 2

10% reduction in recurring defect occurrences

THE BIG WIN

Major Outcomes for Shriji

800+ Parts/Minute

 

Achievedhigh-speed inspection without throughput loss.

10% Reduction in Defect Occurrence

 

Continuous feedback loop drives improvement.

$10K Annual Cost Savings

 

Reduced rework and scrap losses.

ROI Achieved in 18 Months

 

Fastpayback through efficiency and quality gains.

Get in Touch with us about this Testimonial

Let’s build smarter, safer factories. Manufacturing, packaging, pharma-wherever you are, we’re ready to drive your digital shift.
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