Catch defects in real time
Identify problems on the line before they become wasted batches or recalls.
Case Study · Quality Intelligence
From manual checks to machine vision: Cutting Waste on the Pharma Production Line
How a global pharmaceutical manufacturer used computer vision to catch defects in real time, cutting waste and downtime on its production lines.
The challenge
Our client’s challenge
A few production mix-ups a year were costing a Fortune 500 pharmaceutical manufacturer millions of dollars in wasted batches and recall risk.
Quality control depended on manual visual checks, repeated several times a day along each production line. The process was labor-intensive and error-prone, and it kept skilled employees away from higher-value work.
Key objectives
Keep lines running
Reduce the errors and delays tied to manual inspection.
Redeploy skilled staff
Automate routine checks so people can focus on higher-value tasks.
The solution
The AI Collaborator solution
AI Collaborator took the client from proof of concept to a scalable inspection roadmap, drawing on specialists in Germany, Belgium, Italy, and the U.S.:
- 1
Proof of concept
End-to-end testing showed a faster, more affordable approach than alternatives proposed by top research institutions.
- 2
Built on what’s there
Machine vision was integrated with the client’s existing cameras and production systems, keeping disruption to a minimum.
- 3
Tuned to the line
Working with on-site teams, algorithms were customized for each production environment to maximize accuracy and reliability.
- 4
Real-time detection
Advanced image recognition flags defects as they happen, cutting inspection error rates.
- 5
Roadmap to scale
A clear plan for expanding across facilities with minimal overhead and a defined return on investment.
The results
Our client’s results
Real-time inspection gave the client earlier warning on production issues and fewer costly surprises:
Less waste
A sharp reduction in wasted batches and the costs that come with them.
Less downtime
Fewer disruptions and faster decisions when issues appear.
Better use of people
Labor-intensive inspection steps are automated, and staff are redeployed to higher-impact work.
Keep exploring
More AI in production
Consumer Electronics
From a week to minutes
How a global consumer electronics leader turned millions of dollars in secondary research into insights its teams can act on in minutes.
Read the storyEntertainment & Media
Smarter segments, bigger reach
How a leading advertising brand replaced trial-and-error targeting with smart segments that scale campaign reach while holding performance.
Read the storyConsumer Electronics
Which marketing drives revenue?
How a global technology brand isolated the true revenue impact of its marketing and improved targeting accuracy 2.66x.
Read the story
See how MARCO® can help you catch costly defects before they leave the line
Bring a quality or inspection process that still runs on manual checks. We’ll map the path to real-time detection.