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.
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.
THE 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
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.
Industry
General Manufacturing
Deployments
Kompass (AI) enables Tigris
Results 1
>99% Defect detection sensitivity
Results 2
Resource cost savings with automated sorting & traceability
THE BIG WIN
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.
28 Variants on One System
A unified hardware setup enables seamless variant switching with zero changeover downtime
120 Parts Per Minute Throughput
High-speed dual-face inspection fully aligned with production scale and takt-time demands.
>90%Reduction in Operator Mundane Workload
Automated inspection eliminates fatigue-driven errors while boosting productivity and morale.
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