Customized Vision Inspection System for Multinational CPG Manufacturer

A consumer products manufacturer needed a customized vision inspection system on a personal care product line that could be duplicated for multiple systems. EPIC Systems provided a scalable and efficient automated vision inspection solution, enhancing quality control and enabling global standardization for the customer’s personal care product lines.

Hygienic Process System Design

Project

Overview

  • Industry: Consumer Goods
  • Company Size: Fortune 500
  • Location: USA
  • Customer Use Case: Web Forming

Customer’s

Challenge

A multinational consumer packaged goods (CPG) manufacturer sought a custom machine vision system for their personal care product line. The system needed to inspect products with varying sizes and shapes, identify defects as they formed in subcomponents, and signal the production line to reject defective items. Furthermore, it was essential to separate defective products and package them into separate bags and boxes from defect-free products. The system also needed to be replicable for deployment across multiple production lines globally. 

Epic

Solution

EPIC Systems delivered a comprehensive solution by performing a preliminary design phase to ensure the most efficient process and accurate cost estimation. After thorough analysis of the production line and collaboration with the customer to define objectives, EPIC developed an implementation plan incorporating several critical elements: 

  • Custom Defect Identification: Cameras were programmed individually to detect specific defects at various stages of the production process. 
  • Standardized Mechanical Design: A universal mounting system and camera programming were designed to create easy-to-install kits. 
  • Lighting and Optics Study: A robust study was conducted to determine optimal lighting and optics configurations to ensure consistent defect detection across multiple installations. 
  • Standardized Programs and Hardware: Unified camera programs and calibration procedures enabled global rollout of hardware and software with consistent performance. 
  • Global Deployment Readiness: Kits were designed for simple, self-installation by the customer’s team, without requiring EPIC’s direct supervision. 

EPIC’s vision lab conducted multiple tests to determine the ideal lighting strategies, camera angles, and bracket configurations to ensure consistent and accurate defect detection. Once the system proved capable of reliably meeting customer expectations, standardized kits were developed for seamless global implementation. 

Project

Impact

  • Enhanced Quality Control: The custom vision system reliably detected defects in subcomponents at various stages of production, ensuring only defect-free products proceeded to final packaging. 
  • Seamless Product Segregation: The system enabled defective products to be automatically removed from the line and packaged separately, maintaining product quality integrity. 
  • Scalability and Global Deployment: Standardized kits with preprogrammed cameras and universal mounting hardware allowed the customer to install the system across multiple lines without the need for direct EPIC oversight. 
  • Cost and Time Savings: By minimizing on-site engineering requirements and streamlining installation processes, the solution reduced implementation costs and accelerated deployment timelines. 
  • Repeatable Performance: The lighting and optics configurations ensured robust and repeatable performance across different production environments and operating conditions. 

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Our Solutions

EPIC Systems is a multidisciplinary engineering integrator specialized in industrial automation for process manufacturers. We deliver solutions in the following areas:

Process Systems

Machine Vision

Robotics

Industrial Automation