Troubleshooting Automated Visual Inspection machines

Why Automated Visual Inspection machines fail and how to fix them 

AVI systems, are complex integrations of hardware, software, and process know-how. Common issues include: 

• High false rejection rates: Machines may incorrectly flag good products as defective, leading to unnecessary waste and downtime (when optimizations are required). 
• Missed defect detection: Critical defects like cracks, product mix-up, particulate matter or cosmetic defects, like scratches or dirt, can slip through if parameters aren’t optimized. 
• Qualification and compliance gaps: Meeting GMP, EU Annex 1, and USP standards requires robust validation and documentation, which can be daunting during audits. 
• Difficult-to-inspect products: Opaque, colored, or irregularly shaped containers often challenge both manual and automated systems. 

eyetec’s Proven approach to troubleshooting 

Our team’s troubleshooting process is rooted in deep technical expertise and hands-on experience across global markets: 

• Process analysis & optimization 
  Robin and Wouter begin by thoroughly analyzing the current inspection process, reviewing machine parameters, and identifying possible issues. 

• Recipe configuration & fine-tuning 
  In Africa, Robin configured and fine-tuned inspection “recipes”—the set of parameters that govern camera settings, rotation speeds, and defect thresholds. The goal: maximize sensitivity to real defects while minimizing false rejects. 

• Qualification support with realistic test sets 
  In the Nordics, eyetec’s defect sets, containing a range of typical flaws, were instrumental in validating an AVI system’s effectiveness. By simulating real-world defects, our team provided essential support, enabling the client to continue executing their qualification process. 

• Specialized strategies for difficult products 
  For complex cases like viscous products in syringes or flexible infusion bags, Robin and Wouter develop custom inspection strategies. This includes engineering runs to optimize parameters and, when needed, leveraging particle-seeded test samples to mimic challenging defect scenarios

Case Study: Tackling complex inspections

Robin and Wouter recently collaborated on a project in eastern Europe involving AVI systems for viscous syringe products, a notoriously difficult application. By fine-tuning system parameters and adapting inspection protocols, they enabled the client to achieve optimal defect detection without increasing false rejects, demonstrating eyetec’s expertise in handling even the toughest inspection challenges.  

Also read our blog: eyetec’s Vision Engineer Robin: Tackling Visual Inspection challenges around the globe 
 

The eyetec advantage 

• Lifecycle support: From initial process analysis to qualification support and continuous improvement during the lifecycle of inspection systems. 

• Regulatory alignment: Our solutions are always designed with GMP, EU Annex 1, and USP compliance in mind, giving QA managers peace of mind during audits. 

• Tailored consultancy: We don’t believe in one-size-fits-all. Each troubleshooting project is customized to the client’s product, process, and regulatory requirements. 

• Global reach, local expertise: With projects spanning Asia, Africa, North America and Europe, our consultancy team brings international best practices to every engagement.