See How a Pharma Manufacturer Found Hidden Bottlenecks
AI video analytics revealed contamination risks, manual interventions,
and safety violations that traditional systems missed. This unlocked up to 40% potential reduction in downtime.
Unexpected stoppages and contamination risk on a semi-automated bottling line
Fully autonomous line with minimal operator intervention
Pharmaceutical Manufacturing
Cleanroom, high-throughput liquid packaging
What Changed With Pacefactory?
Before
Manual restarts were common
Frequent cleanroom violations
Downtime blamed on wrong stations
After
Video showed root causes in real time
Safety and contamination risks flagged
Operators refocused on value-added work
The Bottling Line Was Stalling and No One Knew Why
Sensors missed cascading delays caused by buffer imbalances
Operators stepped in constantly, increasing risk of contamination
Faults in labeling and filling appeared disconnected, masking root causes
Diagnosing the Real Problem with Bottleneck Analysis
Traditional machine monitoring systems rely heavily on sensor data, machine states, and manual operator input. While this gives visibility into what happened, it often fails to explain why, where it started, or how long it’s been building up across the line.
To uncover the hidden sources of inefficiency, Pacefactory deployed its Bottleneck Analysis capability - a structured approach designed to deliver rapid, end-to-end visibility of production flow.
Analyze the Entire Line to Spot Where Flow Breaks
Pacefactory began by capturing video footage across the full bottling line. The system tracked product flow, operator presence, and machine status indicators like signal lights. This allowed the team to detect where blockages, delays, or inconsistencies were occurring - identifying the precise stations that disrupted the line’s rhythm.
Zoom In on Problem Stations for Root Cause Diagnosis
Once the critical stations were identified, Pacefactory focused its analysis on those machines. By observing video footage frame-by-frame and correlating it with machine signal lights and operator actions, the system revealed the true causes of downtime - whether it was machine faults, lack of supply, downstream blockages, or unnecessary manual intervention.
Quantify Losses with Visual Evidence
Each type of downtime was quantified in terms of duration and frequency. Pacefactory tracks product count, flow speed, and machine status using stack light signals. When flow breaks occur - due to faults, starvation, or blockages - they’re visualized on the timeline.
Visual Evidence. Real-Time Insight.
High downtime at filler (69%), with most linked to recurring machine faults
Labeler delays traced to upstream starvation—not internal issues
Bottle orientation bottlenecks often linked to downstream pileups
Operators entered clean zones without PPE during intervention events
Up to 40% Downtime Reduction Opportunity Identified
54%
downtime is due to downstream blockages.
52%
downtime is tied to preventable machine faults at the filler station.
37%
downtime is caused by starvation due to delays at the filler.
Protects individual privacy
Works with existing cameras
What we found
Impact Across the Pillars
Reduced downtime and increased throughput.
Achieved a 12% reduction in cycle time by eliminating unnecessary delays
Reduced manual handling by reassigning repetitive tasks to automation
Fewer violations, safer floor behavior.
Reduced PPE violations by 65% after automated video detection
Eliminated unauthorized entries in restricted zones through real-time alerts
More consistency, fewer defects.
Achieved a 12% reduction in cycle time by eliminating unnecessary delays
Flagged unverified CIP cycles, resulting in improved audit scores
The Privacy-Safe Way to Use AI on the Factory Floor
Pacefactory’s patented Ghosting feature anonymizes operators in real time, masking individuals while preserving everything that matters for safety, efficiency, and quality.
review
Ghosting completely changed how we approach safety. Instead of pointing fingers, we could finally focus on behaviors and patterns. People felt secure knowing their identity wasn’t being tracked—and that sense of trust helped us build a real safety culture across the floor.
Get ready
Want to See Bottlenecks Like This in Your Facility?
Book a demo and see how video analytics can uncover the issues no one else sees.
Often works with your existing cameras. Fully on-premise for data control and compliance.
