| 704.636.9666

Manual Processes Increase the Risk of Product Defects

Manual processes at the workplace often times can result in physical damage to products. Defects in products will consequently cause financial losses as well as failed production targets. Product defects resulting from manual processes could have dire effects on a company’s operations.

Manual Material Handling

In the workplace, manual material handling can be viewed as the process where a human operator is required to lift, push, pull, lower, or carry products from one place to another.  Some companies involve a lot of physical handling of products, which is usually very risky, not only to the product at hand, but to the employees as well.

Humans are Prone to Errors

Humans are usually prone to errors. When too much physical handling of products is involved, defects will generally occur during normal business operations. Some industries involve higher damage risks when compared to others.

For example, in Canada alone, there are about 250  food recalls per year, where some of the recalls are as a result of poor physical handling. Health Canada statistics show that some of the recalls recorded are a result of mislabeling of products, and other manual handling errors resulting from lack of proper automatic testing procedures. In the United States, food product recalls are also caused by product contamination and label discrepancies.

Physical Packaging Defects

Products are also damaged during physical packaging by company employees. In several cases, when a product is damaged during packaging, an employee will not report the defect to the managers for the fear of losing their jobs or part of their salary as compensation. It quite simply could be an issue of human error.  Thus, damaged products end up reaching the customers and consequently prompts recalls. Recalls over product defects can lead to millions in costs as well as brand damage.

Use Automatic Machine Vision Testing

Based on the risks involved with the physical handling of products and their potential adverse effects, companies should focus on automating their testing processes. Companies can incorporate automated vision inspection on their production lines. This will increase efficiency and productivity while eliminating human errors. Automating operations will result in time and cost saving that would have been impossible with manual processes. Automation and testing will also increase a company’s standard compliance levels.

If you would like to enhance your product testing procedures, contact us today.


A critical key to the success of VGR applications is finding the best architecture for Read more
Position Overview Integro’s Vision Systems Architect (VSA) is a member of the vision systems solutions Read more
Check out the latest in modern Machine Vision in this podcast with an interview with Read more
INCLUDED IN THIS EDITION ✓ What is machine vision, and how can it help? ✓ Top Read more
Have you been looking for a solution to your speed and efficiency in your manufacturing Read more
Production logistics is the management of materials or products from shelf to completion for outbound Read more