Pharma
Resolving a critical manufacturing line issue
Background
A high-throughput production line was experiencing intermittent defects, and every hour of disruption carried a significant commercial impact. The fault appeared only at full operating speed and could not be recreated in an offline test environment.
Challenge
Line speed prevented operators from seeing the fault as it occurred.
- At full production speed, the fault was invisible to operators
- The root cause was intermittent and highly non-obvious
- Traditional inspection and monitoring tools produced no actionable insight
- The team needed to capture the real event under live production conditions and connect it to the resulting defect
Solution
PurpleSector deployed F1™-derived high-speed vision sensors at critical locations on the line.
The sensors recorded detailed, time-synchronised footage while the process ran at full speed. A bespoke performance-analysis algorithm then correlated the sequence of events with the observed outcome, allowing the failure mechanism to be isolated.
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Results
The root cause was identified and resolved within one hour.
Defects were eliminated at full production speed, waste was reduced to zero, and the line returned to stable, predictable operation the same day.
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