Case Study: a-eye Clearance Solution for Vial Packaging Line

A pharmaceutical manufacturing site in Europe, part of a global company specializing in innovative and reliable pharmaceuticals, sought to improve its packaging line’s efficiency and consistency. This facility previously relied on manual procedures for line clearance but recognized an opportunity to upgrade to automated line clearance when a new packaging line was introduced. The goal: to streamline line clearance on its vial packaging line for reduced time and error rates. SEA Vision was tasked with designing and integrating an automated solution using a-eye Clearance.

Read the full case study⬇️

Machine

• Type: Handling Machine
• Function: Collects vials and booklets into pucks for efficient feeding to a top-load cartoning machine
• OEM: Marchesini Group

Challenges Faced by the Facility

Manual Process

Before implementing a-eye Clearance, the line clearance process was manual and involved several steps:

• Clearing and Cleaning: Conducted according to paper-based procedures and checklists.
• Manual Verification: Operators inspected machine belts and components between batches to confirm no residues remained.
• Documentation: Paper modules were signed by operators as evidence of line clearance.

Issues with Manual Process

• Time-Consuming: Manual inspection took about 45 minutes, slowing down the shift between batches.
• Labor-Intensive: The dependence on manual processes increased variability and labor costs.
• Error-Prone: Reliance on visual checks made consistent identification of residues and misplaced components difficult, impacting process accuracy.

Challenges Faced by SEA Vision During Implementation

SEA Vision encountered technical and operational challenges in adapting the robotic handling machine for automated clearance:

• Obstructed Views: The robot arm’s positioning during stops obstructed camera views.

• Flat Surfaces: The machine base's flat surfaces allowed product accumulation in concealed areas.
• Inaccessible Areas: Certain enclosed machine parts couldn’t be reached by automatic inspection, requiring occasional manual intervention.

Solution

To address these challenges, SEA Vision worked closely with the OEM to adapt the machine for automatic clearance control. The a-eye Clearance system uses strategically positioned cameras and AI algorithms, ensuring a residue and component-free machine base with enhanced clearance accuracy.

Technological Components

• Cameras: Ten cameras cover the machine base. Six cameras provide a top-down view of transport belts.

• AI Algorithms: Automated image analysis identifies and detects production items or foreign objects within the machine.

Operational Features

• Dynamic Image Acquisition: Captures multiple images as the robot moves to inspect obstructed areas.
• Mechanical Optimization: Slopes and additional surfaces prevent residue accumulation.

• Supplementary Checks: Blind spots are monitored with sensors, and a QR code scanner allows for quick manual acknowledgment.

Digital Integration

• Image Processing: Captured images are processed by AI, with alerts displayed for any items detected.

• Digital Checklist: An on-screen checklist guides the operator through tasks, which can be set up and customized easily by the facility team.

Results

Efficiency Gains

• Reduced Downtime: Automated clearance reduces batch-switch downtime.
• Error Reduction: Consistency is improved, with fewer human errors.
• Speed: Automated inspection reduces clearance time from 30-45 minutes to just a few minutes per machine.

Operational Improvements

• Paperless System: Transitioned from paper-based records to a fully digital process.
• Guided Procedure: Clear, on-screen instructions ensure consistent line clearance.
• Data Certainty: Clear digital records offer traceable evidence for compliance.

Compliance and Validation

• GMP Integration: Validated according to ISPE guidelines for AI systems to meet GMP standards.
• Validation Strategy: After an initial parallel period with manual checks, the solution was fully implemented. Operators were given time to adapt to the system alongside traditional procedures, ensuring a smooth transition.

Conclusion

The implementation of a-eye Clearance has enhanced the line clearance efficiency and consistency in this facility’s robotic handling machine operations.

By automating the process with AI and advanced cameras, downtime and error rates were reduced, supporting GMP compliance. The automated transition has optimized efficiency and established a scalable model for potential application on additional lines.

Learn More

For further information about our AI-powered automated line clearance, visit:

• AI-Driven Automated Line Clearance