AI-driven vision automation enabling 100% inspection accuracy and fully optimized production throughput by SunBio IT Solutions.
Client: Top Manufacturing Industries
Industry: Premium Home Fragrance & Product Manufacturing
Technology Provider: SunBio IT Solutions (Bengaluru, India)
Manual visual inspection at the wax-filling stage led to alignment inconsistencies, human errors, and reduced throughput. The process required dedicated QC personnel and created a bottleneck in achieving optimal production speed.
SunBio IT Solutions implemented an industrial vision automation solution featuring real-time object detection using dual high-speed GigE cameras and machine learning models trained specifically for high-precision candle alignment and counting.
Partnering with SunBio IT Solutions delivered immediate, verifiable improvements across manufacturing lines:
| Metric | Before Automation | After Automation | Improvement |
|---|---|---|---|
| Inspection Accuracy | ~95% | 100% | Error Eliminated |
| Inspection Time | 15s / tray | <4.5s / tray | 70% Faster |
| Rework Rate | 3.2% | <0.1% | 97% Reduction |
| QC Labor | 2 Operators | 0 Dedicated | Reallocated Resources |
The facility achieved higher production throughput, substantially reduced operational costs, and elevated quality consistency through automation-driven precision.
Got Questions About Our Automation Solutions?
AI vision automation combines high-resolution industrial cameras with deep learning algorithms to inspect products on fast-moving assembly lines automatically, detecting flaws, verifying alignment, and counting items with perfect repeatability.
SunBio designs custom hardware and software bundles—including GigE cameras, PLC triggers, and custom AI inference engines—that seamlessly interface with existing factory conveyor belts and automation controls.
Manual visual inspection at the wax-filling stage led to alignment inconsistencies, human errors, and reduced throughput, creating a bottleneck in achieving optimal production speed.
SunBio IT Solutions implemented a vision automation solution using dual high-speed GigE cameras and AI models trained for precise candle alignment, counting, and automated gate control.
Achieved 100% inspection accuracy, a 70% reduction in inspection time (under 4.5 seconds per tray), a 97% reduction in rework rate, and complete reallocation of dedicated QC labor.