The challenge
BOSCH Rexroth, a global leader in automation and hydraulics technologies, manages high volumes of components and valves to be shipped to customers worldwide. . In the packaging area, the manual inspection of blisters containing valves – verifying the correct code, counting items, and carrying out visual quality checks of O-rings, seals, rings, orientation, and sequence – required time, a high level of operator attention, and remained exposed to the risk of human error, particularly during peak production periods. The company was seeking an automated solution capable of ensuring traceability, repeatability, and inspection speed, without slowing down the packaging flow.
The solution
The PIQAPART team developed and installed a bespoke LightBox solution within the packaging area. The operator places the blister containing the valves inside the LightBox. A controlled lighting system and an industrial camera capture the image of the blister, which is analysed in real time by artificial intelligence models specifically trained on the different BOSCH Rexroth valve families.
The system automatically performs:
- code verification, matching the order code with the type of valve contained in the blister;
- automatic counting, checking that the number of valves corresponds to the required quantity;
- visual quality inspection, verifying the presence and position of O-rings, seals, rings, and other components, and checking orientation and the correct sequence within the blister.
The application
The LightBox was integrated into the existing operational workflow with minimal impact on operators’ working methods. The operator positions the blister inside the LightBox, the system captures the image and automatically initiates the analysis.
Within seconds, the operator can view the inspection outcome on the monitor:
- number of valves detected;
- number and type of non-compliant valves;
- compliance status in relation to the order being processed.
In the event of an anomaly – incorrect quantity, wrong valve type, missing or incorrectly positioned O-rings or seals, or incorrect assembly sequence within the blister – the system immediately flags the issue, allowing the operator to intervene before the batch is closed and dispatched.
The results
The introduction of the PIQAPART LightBox solution delivered several measurable benefits:
- reduced packaging mistakes thanks to objective and repeatable inspection of every blister;
- increased efficiency in the packaging area, with shorter inspection times compared to manual checks alone;
- enhanced operator support, with clear and immediate on-screen feedback and precise indication of any non-compliant items;
- improved traceability, with each inspection linked to the order, valve code and inspection outcome.
A particularly significant benefit concerns after-sales management: for each order, the system stores the captured images together with the corresponding analysis results. In the event of claims relating to incorrectly assembled products or orders containing fewer valves than declared, BOSCH Rexroth has objective evidence of how the blister was inspected, packaged and shipped. This reduces unfounded disputes, speeds up claims handling, and strengthens customer loyalty.
The conclusion
The BOSCH Rexroth project demonstrates how PIQAPART can be effectively integrated into packaging areas to automate component counting and quality control. Thanks to the dedicated LightBox, the company can now ensure that every valve blister complies with order specifications in terms of quantity, type and component quality, increasing process reliability and further consolidating the standards of excellence recognised by the market.