The mass production of medical liquids in transparent pouches requires seamless, regulatory quality to ensure patient safety. Every container must be inspected.
Manual inspection as an inefficient solutionThe current manual inspection of medical liquids in transparent pouches is a time-consuming and labor-intensive process. Human inspectors tire quickly, leading to errors and inconsistencies in quality control. The limited inspection speed also slows down production lines considerably. In addition, the documentation of inspection results is often inadequate, which makes traceability difficult in the event of problems.
Human error and quality risksStudies show that human inspectors can miss up to 30% of particles when visually inspecting medical fluids in transparent pouches. This poses a significant risk to patient safety, as even the smallest impurities can lead to serious complications. Such errors can result in expensive recalls and legal consequences for manufacturers. Another critical factor is the decreasing concentration of human inspectors over time. Fatigue leads to an increased error rate, especially in monotonous tasks such as particle inspection.
Inefficiency and costsThe high labor requirements and slow inspection speed of manual quality control of medical fluids in transparent bags lead to significantly increased production costs. Faulty inspections that miss particles can lead to rejects, rework and, in the worst case, production downtime. These problems not only affect efficiency, but also increase the risk of recalls, with significant financial and reputational consequences.
Additional considerationsThe requirements for documentation and traceability of inspection results are being increased by ever stricter regulations. This requires the complete recording and storage of data to ensure compliance with quality standards and legal requirements.
A precise camera setup, consisting of carefully selected lenses and optimized lighting, captures images of the medical bags on the production line. These images are also captured as the bags move, enabling inline inspection.
Real-time analysis by AIThe captured images are analyzed in real time by a specially trained, proprietary Artificial Intelligence (AI). The AI is designed to detect particles of different sizes, shapes and material properties in the transparent liquids. In addition to detection, the particles are also documented to ensure complete traceability.
Automated reporting and user interfaceAt the end of each production batch, a detailed report summarizing the inspection results is automatically generated. At the same time, the ongoing results are displayed in a user-friendly graphical user interface (GUI). This allows operators to monitor the inspection process in real time and intervene if necessary.
The combination of multiple scanner sensors provides an innovative way to ensure accurate imaging for different particles and other foreign bodies. The images created form the basis for a comprehensive AI solution for automatic analysis.
UIA customized graphical user interface (GUI) visualizes all specified defects. This enables operators to check the inspection results intuitively and efficiently
Robust evaluations with multi-view AICustomized data curation and multiview AI training provide a reliable multiview AI model for particle detection. Our AI models are specially trained to detect and distinguish between specific particles. In particular, the models learn to distinguish between particles and permitted structures such as folds in the bag, air bubbles and lettering.
APIThe entire inspection system is smoothly integrated into existing production lines without affecting the production flow. By using APIs, data transfer and processing takes place in real time, enabling an immediate response to detected defects. Automated process control and seamless data integration into existing systems ensure efficient quality control without production delays.
Automated control is faster and more efficient than manual control by employees and requires fewer personnel. This significantly reduces process costs. K|Lens sees a reduction in inspection costs of around 90% for the operator.
The detailed inspection data enables the optimization of manufacturing processes. This increases efficiency and reduces production costs.
AI-supported analysis minimizes errors that can occur during manual inspection. This leads to consistent and reliable particle detection.
The AI models are specifically trained to detect particles and distinguish them from harmless structures such as air bubbles or wrinkles. This reduces the risk of false alarms and pseudo rejects.
K|Lens relies on inline inspections in the customer's cycle time.
The user-friendly GUI enables continuous monitoring of the inspection process. This enables a quick response to potential problems and minimizes downtime.
The system automatically generates detailed reports on the inspection results. This ensures complete documentation and traceability.
Comprehensive data logging supports compliance with regulatory requirements. This makes it easier to trace products and analyze production processes.
Accurate particle detection helps to ensure the safety of medical fluids. This minimizes the risk of complications for patients.
Early detection of contamination reduces waste and the risk of costly recalls. This protects the company's reputation and minimizes financial losses.
Smooth integration into existing production lines enables efficient quality control without production delays. Automated process control and seamless data integration into existing systems ensure a smooth process.
