Machine vision case studies
See how the EagleEye® platform’s point-and-click interface delivers easy-to-train, high-accuracy quality control across automotive, pharma, FMCG, and other manufacturing sectors.
Recently Posted Case Studies
ENGINEERING TOOLSVision Inspection for Precision Tweezer Manufacturing
EagleEye Platform · Dual GigE Cameras · 5-Stage Vision Pipeline This case study documents the design and deployment of the EagleEye Inspection Platform, an AI-powered automated quality inspection system developed by Qualitas Technologies for a global manufacturer of precision personal care tools. The platform employs dual industrial cameras and a five-stage vision pipeline to evaluate every tweezer across five critical quality parameters at production speed, replacing subjective manual inspection with objective, data-driven pass/fail determinations and complete traceability.
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AUTOMOTIVESpark Plug End-of-Line Inspection
Three-station automated inspection — loading, Keyence top + front vision, and intelligent mark-and-reject — delivering zero-PPM quality at 20 parts per minute.
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FMCGAI-Powered OCR for Cigarette Packet Data Extraction
This application note examines the inspection challenge, current approaches, a modern machine vision architecture, and expected outcomes.
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FMCGAI-Powered Grain Analyzer for Rice Mills
This case study presents the design, development, and deployment of an AI-powered Grain Analyzer that combines computer vision, deep-learning detection and segmentation, real-time processing, and seamless hardware integration to deliver objective, granular, and actionable insights into rice quality at industrial throughput.
READ MORE →Machine Vision Case Studies
ENGINEERING TOOLSVision Inspection for Precision Tweezer Manufacturing
EagleEye Platform · Dual GigE Cameras · 5-Stage Vision Pipeline This case study documents the design and deployment of the EagleEye Inspection Platform, an AI-powered automated quality inspection system developed by Qualitas Technologies for a global manufacturer of precision personal care tools. The platform employs dual industrial cameras and a five-stage vision pipeline to evaluate every tweezer across five critical quality parameters at production speed, replacing subjective manual inspection with objective, data-driven pass/fail determinations and complete traceability.
AUTOMOTIVESpark Plug End-of-Line Inspection
Three-station automated inspection — loading, Keyence top + front vision, and intelligent mark-and-reject — delivering zero-PPM quality at 20 parts per minute.
FMCGAI-Powered OCR for Cigarette Packet Data Extraction
This application note examines the inspection challenge, current approaches, a modern machine vision architecture, and expected outcomes.
FMCGAI-Powered Grain Analyzer for Rice Mills
This case study presents the design, development, and deployment of an AI-powered Grain Analyzer that combines computer vision, deep-learning detection and segmentation, real-time processing, and seamless hardware integration to deliver objective, granular, and actionable insights into rice quality at industrial throughput.
ENGINEERING TOOLSInspection of Tapered Roller Bearings for a Global Bearings Manufacturer
The customer, the Indian division of a global bearings manufacturer, approached Qualitas for a solution to automatic visual inspection of tapered roller bearings. The bearings were being produced in large numbers and needed to be in-line visually inspected for manufacturing surface defects on the cylindrical and larger flat surface.
AUTOMOTIVECounting Piston Rings with 100% Accuracy Using Machine Vision
Our client is an American developer, manufacturer, and supplier of products for automotive, commercial, aerospace, marine, rail, and off-road vehicles and power- generation applications. Piston rings maintain gas compression between the piston and the cylinder wall. They seal the cylinder so that combustion gas generated at the time of ignition does not leak into the opening between the piston and the cylinder.
PHARMALabel Inspection of Pharmaceutical Products
Our client is an Indian multinational pharmaceutical company that manufactures healthcare products and distributes them across countries and different corners of the world. It is one of the leading manufacturers of healthcare products promising the best quality of deliverables. Labels of manufactured products contain the details of the products like batch number, manufacturing date, expiry date and MRP. This information needs to get recorded for tracking and traceability.
PHARMAVial Counting Using Image Processing to Improve Inspection Accuracy and Reduce Downtime
Accurate counting is important for process control, inventory control, and product reconciliation, to minimize any possible loss of high-value products. The requirement of the client was to count the more than a hundred types of vials placed on the trays with an automated system to improve the accuracy rate and reduce cycle time –
STEELAutomated Steel Strip Inspection Using AI and Vision System
The client is a fully integrated flat carbon steel manufacturer in India operating at 10 million tonnes annually, encompassing ore beneficiation, pellet making, iron making, steel making, and downstream facilities including cold rolling mills and galvanizing operations.
OIL & GASSurface Inspection of LPG Cylinders Using Machine Vision & AI
Our client is a Fortune 500 Company and is a major player in the Refining and Marketing of petroleum products in India. The Company today is a fully integrated entity after the incorporation of upstream subsidiary Bharat Petro Resources Limited. The Company today offers fully integrated operations with the incorporation of upstream subsidiary Bharat Petro Resources Ltd. in 2005.
ELECTRONICS3D Inspection of Soldering Paste Using an AI-Based Machine Vision System
Our client is an American global automotive electronics supplier and Fortune 500 company established in 2000. They are composed of multiple businesses that design, engineer, and manufacture vehicle cockpit electronics products and connected car services for a diversified customer base, including all of the major automakers worldwide.
ELECTRONICSPackaging Inspection — Machine Vision Automates TV Packaging QC
Our client plays an active role in world markets with its assertive global business policy. As a result, it controls 114 local subsidiaries worldwide, with roughly 82,000 executives and employees. With 2013 global sales of USD 53.1 billion (KRW 58.14 trillion), the company operates its business through five divisions: Home Entertainment, Mobile Communications, Home Appliance, Air Conditioning and Energy Solution, and Vehicle Component.
LOGISTICSCount the SKUs in a Pallet
Our client is a niche management consulting firm focused on helping organizations solve business problems through technology & process solutions. As seasoned professionals having diverse industry, solution and product experience, they pride themselves on being effective business liaisons.
LOGISTICSAutomation for Label Classification Using AI and Computer Vision
Our client is a leading company in the packaging industry. It was established in 1983 and headquartered in Bangalore, Karnataka. It has seven manufacturing plants located in Baddi, Pantnagar, Guwahati, Manesar, and Karnataka, which have over 5,000 employees. The estimated revenue is Rs. 1,100 billion.
AUTOMOTIVEMachine Vision Automates Engine Housing Dimensions
Our Client started in 1993 as a consultancy. The Company quickly zeroed in on ‘Optical White light Scanning’ from Rexcan III to bring in latest technologies at the doorstep of Indian Industry in the field of Scanning, Measuring and Product Development.
ELECTRONICSDimensional Measurement of Ferrite Core
Our client is a leading electronics company based in Tokyo, Japan. It was established in 1935 to commercialize ferrite, a key material in electronic and magnetic products. They develop, manufacture and market electronic components and systems, focusing on technology markets that include automotive, industrial, and consumer electronics, as well as information and communications technology. Today, In India, they are a healthy 800+ Crore company with close to 2250 employees in three factories and five sales offices throughout the country, as well as a strong network of dealers.
OIL & GASImage Processing Based OCR Automation For Reading Tare Weight On Cylinders
As the leader in the manufacturing industry, the client manufactures and recycles the LPG cylinder with the help of automation. Being focused on the quality they have set a bar of unwavering commitment in customer services and quality. A cylinder is a household item used on a daily basis. Tare weight is the weight of an empty cylinder(without the weight of the gas), which is painted on the body of the cylinder.
FMCGLabel Inspection In Beer Bottles – Case Study
The client is one of the largest beer brewing companies and has been known for the quality of its products. The headquarters of the organization is in Brussels. In the year of 2020, the produced net revenue was 26.4 billion U.S. dollars.
FMCGLabel Inspection In FMCG Products – Case Study
The client is among the largest FMCG companies around the world with a customer base of more than 2 billion USD. Having such a large customer base, the client is committed to constantly improving the quality standards to enhance users’ experience with their products.
LOGISTICSPRINT DEFECT IDENTIFICATION USING VISION INSPECTION
Our client specializes in design for additive manufacturing and is the only source for certified Solidworks professionals on-demand. It is also an authorized value-added reseller for HP and Markforged 3D printers. Their support capabilities include design, analysis, prototyping, product & process development. These capabilities can be utilized individually or combined, providing clients with a complete engineering solution on-demand.
AUTOMOTIVEEngine Block OCR Inspection – Case Study
The company is the third-largest two-wheeler manufacturer in India manufacturing a wide range of vehicles from mopeds to racing-inspired motorcycles. They also manufacture three-wheelers. They have an annual production capacity of 4 million 2 wheelers & 120,000 three-wheelers. It is one of the leading two-wheeler and three-wheeler exporters from India, distributing to over 60 countries.
AUTOMOTIVEClassification of Automotive Parts with AI and Computer Vision
Our client is a multinational motorcycle company headquartered in Chennai, India. It is the third largest motorcycle company in India with a revenue of over ₹20,000 crore in 2018-19.The company has annual sales of 3 million units and an annual capacity of over 4 million vehicles and more than 1,00,000 as their employees.
ENGINEERING TOOLSPaper Defect Inspection- Case Study
Our client is a leading supplier of transformer board, molded and machined parts, sets and kits and electrical insulation paper to Indian and International markets all used for transformer applications. The company commenced manufacture in 1980 with technical know-how from Rogers Corporation, USA who were among the prime suppliers of insulation to large transformer companies in North America and Europe. Subsequently, they have developed and introduced a range of products for transformer insulation independently, and today supply virtually every transformer manufacturer in India and many leading transformer companies in Asia.
ENGINEERING TOOLSDefect Inspection on Protein Filter- Case Study
Our client is a specialist engineering service & solutions company servicing clients across a range of engineering segments helping improve their engineering efficiency, support their global footprint and improve their competitiveness. With around 1000 employees, they have emerged as a partner-of-choice for leading international companies.
AUTOMOTIVEPick And Place Components Using Vision Guided Robotics To Increase The Flexibility Of Robotic Systems
Our client is a leading robotic solution provider company in India. It successfully provided solutions to more than 500 clients across the globe. The company has established itself as a reliable automation technology provider to its customers.
ENGINEERING TOOLSRobot Guidance with Integrated Vision System to Pick and Place Components on The Fixed Coordinates
Our client offers turnkey industrial Automation systems and solutions with Industrial Robots. With its passion for excellence and concentrated focus on customer’s requirements, they have transformed from a small start-up to an established technology partner to various renowned clients across India and the world.
PHARMAMachine Vision Automates Protein Filter Inspection – Case Study
Our client is an international pharmaceutical and laboratory equipment supplier, covering the segments of Bioprocess solutions and Lab products and services. In 2018, the technology group earned sales revenue of 1566.0 million euros. Founded in 1870, the Gottingen-based company currently employs around 8,125 persons.
ENGINEERING TOOLSRobot Automation Assistance – Case Study
Our client offers turnkey industrial Automation systems and solutions with Industrial Robots. With its passion for excellence and concentrated focus on customer’s requirements, they have transformed from a small start-up to an established technology partner to various renowned clients across India and the world.
PHARMAHigh Speed QR Code Reading with AI and Computer Vision – Case Study
Our client is the largest contract manufacturing pharmaceutical company of India. The organization deals in the manufacturing and export of formulations in a wide spectrum of dosage forms & therapeutic segments. With 5000+ employees, the company is currently supplying to almost all Indian and multinational pharmaceutical companies across the globe. In a span of few years, the organization has become the icon of Indian Pharmaceutical manufacturing industry and currently manufactures around 9% to 10% of the country’s total medicinal requirements.
ELECTRONICSLEAK INSPECTION OF POLYURETHANE FOAM IN REFRIGERATORS- Case Study
The client is one of the largest market players in manufacturing household appliances like refrigerators, ovens, washing machines, etc, across the globe. They promise quality products to their customers with reliable services. Polyurethane foams are filled in between the refrigerator’s outer and inner body to provide insulation.
AUTOMOTIVEEngine Character Inspection – OCR Automation with AI & Machine Vision
Our client is an automobile manufacturer in India. As of July 2018, it had a market share of 53% of the Indian passenger car market. Introduced in the year 1981 to the Indian market and with more than 40,000 employees, our client has been one of India’s most successful automobile manufacturers.
OIL & GASAutomated Bottling of Liquid Petroleum Gas (LPG)
The customer is one of the three largest distributors of portable LPG cylinders, used for cooking by a vast majority of Indian households. Throughout the country, there are numerous cylinder filling stations where empty cylinders collected from households are refilled with a measured amount of LPG and delivered to depots. Qualitas has successfully implemented AI-based automation in critical areas of the labor-intensive, hazardous, and an error-prone cylinder filling process.
ELECTRONICSRefrigerator Panel Inspection- Case Study
Our client is one of the leading consumer electronics manufacturers across the globe and one amongst fortune 50 companies. Their products are sold in more than 80 countries across the globe and they have employed more than 300,000 employees by having a market share of 21.8%.
FMCGInspecting Label Using OCR To Remove Manual Data Entry Of Cigarette Packet Details
Our client is an Indian multinational conglomerate company headquartered in Kolkata, West Bengal and was established in the early 1900s. With over 27,000 employees our client had a turnover of over 1.9 Billion in the year 2019.
AUTOMOTIVESticker Classification Using AI – Case Study
To segregate more than 40,000 stickers a day with 30 variants in the running production line an AI-powered vision system was developed. In the process of segregation, with the help of image-based inspection, the defective stickers were routed to rejection bins. Deployment of this system helped in achieving desired inspection time, on the other hand, it freed human resources that can be utilized for other tasks.
AUTOMOTIVEDetection Of Circlips And Sleeves On Gear Boxes – Case Study
Our client is the largest manufacturer of power-train and engineering precision products. The client is into the design and manufacturing of engines and transmissions and high precision components like cylinder heads, cylinder blocks, crank shafts, camshafts, cam rods and transmission gears for the Automotive, Off-Highway, Defence, Agriculture and Railway industry.
LOGISTICSAutomated QR Code Inspection Using AI Vision System- Case Study
Our client is a German-based multinational engineering and technology company and was founded in the late 1800s. Our client set up their first manufacturing plant in India during the early 1950s. With a turnover of over $3 billion in India and over 31,000 employees, they are spread across 10 locations and 7 application development centers.
OIL & GASPick and Place Cylinders Using An AI-Based Vision System
As a leader in the manufacturing industry, our client has set the bar with its unwavering commitment to quality and exceptional client service. Through their extensive inventory of diverse and customizable products, their talented team goes above and beyond to make sure that their client’s needs are not only met, but exceeded. They offer higher capacity & efficiency at the lowest possible capital and operating costs by consistently working under the principles of Total Quality Management & incorporating a zero-defect culture both in our systems & in the product.
ELECTRONICSRefrigerator Panel Inspection
Our client is one of the leading consumer electronics manufacturers across the globe and one amongst fortune 50 companies. Their products are sold in more than 80 countries across the globe and they have employed more than 300,000 employees by having a market share of 21.8%.
ENGINEERING TOOLSAutomated Inspection of Bearing Rollers with Machine Vision
The client manufactures and supplies bearings, gear drives, belts, chains, couplings, lubrication systems, and related products. Tapered roller bearings can take both axial loads (sideways or thrust forces), as well as radial loads (downward force). Pairs of tapered roller bearings are used in car and vehicle wheels.
LOGISTICSComplete Quality Inspection Automation Using AI and Vision System
Our client has a worldwide network and you can find their ingredients in many global and local leading brands of beverages, dairy products, and bakery products around the world. They are one of the largest Danish suppliers of fruit-based raw materials and semi-manufactures.
FMCGAutomated Inspection Of Pizza Toppings Using AI-Powered Vision System
Our client is from a multinational food service company, who are the largest contract foodservice company in the world, serving around 5.5 billion meals a year in locations including offices, factories, schools, universities, hospitals, major sports and cultural venues, mining camps, correctional facilities, and offshore oil platforms.
FMCGConverting Printed Character Into Digital Form with Image Processing
Our client offers a comprehensive selection of services to provide their customers with complete, single-source solutions for their low voltage needs. Their mission is to provide their customers with a level of quality, service, and attention to detail that is second to none.
ENGINEERING TOOLSInvestment Casting Components Inspection
Our client is a $135 million group of Companies founded in 1945. They are at the forefront of technology and manufacture of investment castings. With fully automated systems and round the clock production capability they provide their customers with unmatched value, quality and service.
FMCGClassification and Quality Evaluation of Tobacco Leaves with AI and Machine Vision
Our client is an Indian multinational conglomerate company headquartered in Kolkata, West Bengal and was established early 1900s. With over 27,000 employees our client had a turnover of over 1.9 Billion in the year 2019.
ENGINEERING TOOLSImage Acquisition Of Wind Turbine Blades
Wind turbines account for more than 6% of the total world's electricity as of 2020. The surface quality blades play a significant role in ensuring seamless motion. To inspect the inner surface of the wind turbine blades, an automated mobile inspection system was developed with the help of a moving cart since the object is large.
ENGINEERING TOOLSAutomating OCR of Banknote Serial Numbers
Banknote Serial Number OCR – Our clients fall into the banking sector. Established in the year 1935, to respond to the economic troubles. The basic function is to regulate the issue of Banknotes and keeping of reserves with a view to securing monetary stability in India and generally to operate the currency and credit system of the country to its advantage.
AUTOMOTIVEOCR Inspection Of Engine Blocks To Track The Engine Details Using An AI-Based Vision System
The company is the third-largest two-wheeler manufacturer in India manufacturing a wide range of vehicles from mopeds to racing inspired motorcycles. They also manufacture three-wheelers. They have an annual production capacity of 4 million 2 wheelers & 120,000 three-wheelers. It is one of the leading two-wheeler and three-wheeler exporters from India, distributing to over 60 countries.
ENGINEERING TOOLSDimensional Measurements Of Nuclear Fuel Pellets Using A Vision System
Our client is the biggest nuclear research center in India. The organization was established in 1954. Being the leader in Nuclear Energy supply, the company manufacturers zirconium fuel pellets to produce energy by fission and fusion.
ENGINEERING TOOLSUV Inspection Solutions with AI and Machine Vision
From a humble beginning in 1998, our client has grown to become a leading global supplier of precision-engineered products using Metal Injection Molding as the core manufacturing technology. Today they have achieved a leadership position in the field of MIM, Providing precision-engineered products to customers in more than forty countries in the Americas, Europe, and Asia.
STEELSteel Pipe Character Reading with OCR Automation
Our client is a multinational steel manufacturing corporation headquartered in Luxembourg City. With more than 2, 00,000 employees, our client is one of the world’s largest steel producers, with an annual crude steel production of 92.5 million metric tonnes as of 2018. They are ranked 123rd in the 2017 Fortune Global 500 ranking of the world’s largest corporations.
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