Driving Quality and Productivity in Contact Lens Packaging with OMRON FH-AI

As production volumes increased, the manufacturer faced growing challenges in its final inspection process for contact lens packaging. Inspection involved verifying multiple parameters, including blister integrity, lens positioning, and label accuracy. These checks were critical to ensuring product safety, regulatory compliance, and brand reputation.

However, the inspection process relied heavily on manual visual checks. Under high-speed production conditions, this approach proved to be slow, inconsistent, and prone to human error. Inspector fatigue and subjective judgement led to a 20% defect rate, creating quality risks and rework.

To maintain inspection coverage, the manufacturer required 12 inspectors across three production lines, resulting in high labour costs and limited scalability. Despite the manpower investment, manual inspection could not guarantee consistent, repeatable results—especially as product variation increased.

The manufacturer needed a solution that could:

• Detect and classify a wide range of defects accurately
• Perform reliable inspection at production speed
• Reduce dependence on human inspectors
• Improve consistency while supporting future scalability