The challenge
In most plants, quality is checked at the end of the line or in the lab. By the time a defect is found, a whole batch has been made, packed and sometimes shipped. Records sit on paper or in a spreadsheet, so tracing a bad unit back to its raw materials takes days, and the recall that follows is wider than it needs to be.
Our approach
Move the check to where the product is made, and make every check leave evidence. Each station samples product by risk, sensors and cameras measure what matters for that product, and the industry's own rules decide what happens to a batch that fails.
- Sensor checks at each station: temperature, weight, pressure, seal and fill
- Cameras on the line scoring surface defects, fill level, label presence and seal integrity
- Industry rulebooks wired in as gates: HACCP critical limits in food, blend uniformity under GMP in pharma, high voltage isolation before dispatch in EV
- A failed check holds the batch automatically; a named person releases, reworks or scraps it
What we built
In-line quality is a module of WAJD Forge, our manufacturing platform. Every unit is checked at its station, every result is recorded against the batch, and statistical process control charts every characteristic with Cp and Cpk capability, so drift shows up before it becomes scrap. From any finished unit, one query walks the movement ledger back to every raw batch and supplier, and forward to every shipment.
Where it stands
Built and running end to end in WAJD Forge on a simulated plant, across food, pharma and automotive industry profiles. The vision check runs through the production interface today with a stand-in model; a trained model is fitted to each client's own products and cameras during deployment, because a defect model is only as good as the images of that line. WAJD Forge is open to design partners.