How AI helps this contract manufacturer to stand out on product quality | Federal Package & Cognex

Federal Package, based in Chanhassen, Minnesota in the United States, is the preferred contract manufacturer for many well-known brands. They specialize in the development and packaging of a wide range of health, beauty, and personal care products including deodorants, sunscreens, lip balms, serums, and a variety of lotions and creams.
Quality is the top priority for Federal Package. They know that their customers trust them with their brand image, and they do not take that responsibility lightly. They take every measure possible to ensure that they deliver superior services and products to their customers. See how Federal Package achieves this level of successful defect detection using Cognex AI and the In-Sight 2800 Vision System.
‪@federalpackage‬
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TRANSCRIPT:
Noah Leuer, Manufacturing Engineer, Federal Package:
“I think here we take just as much pride as the companies that we work with in the products that we make. We like to think of them as our own. We work with small startup companies all the way up to well established brands. If we're not meeting the quality expectations that we have, being a contractor, there's obviously the implication that that there's other companies that make it. We understand that and we have just as high of a quality expectation of our own products.
We deal with a lot of hot filling applications like deodorant or lip balms or things like that, and that can add complications to the manufacturing process. The drips are never the same one to the next. As our output increases and as we work with more customers, we are trying to rely more heavily on automated manufacturing processes and along with that comes in vision quality inspections. The drips being inconsistent necessitated a system that is able to do more of the processing on its side.
What we've been able to do with the edge learning is let the machine do a lot of the hard work. The edge learning allows us to basically load pictures of bad examples and pictures of good examples. We can change over a line to a new product much quicker than we traditionally would be able to. We can have a vision system up and running within 20 minutes, whereas before it would be a full day.”
Jerry Bilse, SVP Operations & Engineering, Federal Package:
“The vision systems we have put in has helped make our best even better than what it was. We now have a deodorant line that runs basically 24 hours a day, five days a week, where nobody's touching the product. If it wasn't for camera systems, we could not do that touch-free. We are not experts in everything. So I view this as a great opportunity for Cognex to help us get better, come in here and say we can help with that. That's where I see huge value going into the future.”
Noah:
“We have a lot more trust in the system as a whole that we're not producing bad parts so we can run a little higher speed. We've gotten to a much higher quality standard. I'm the lines that have these vision systems. Being a contract packager, we don't necessarily know what the product we are making tomorrow or next year will be, but we know that these systems are very flexible and allow us to go into those types of businesses without worrying about being able to make the highest quality product possible.”
Jerry:
“We want to employ the whole person. We don't just want to have them sitting there watching containers go by. We want to deploy automation where it makes sense. And a lot of our people that we have redeployed in that manner are the ones dealing with the automation now.”
#automation #ai #factoryautomation #industrialautomation #iiot
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