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.
The approach
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
Results 2
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.