How AI Transformed Catalyst Inspection At Axens

How AI Transformed Catalyst Inspection at Axens Arabia

Axens Arabia is a global leader in advanced technologies and services for oil refining, petrochemicals, gas processing, and alternative fuels.

Increase In Inspection Accuracy

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Reduction In Downtime

0 %

Cost Savings

0 %

About Axens Arabia

Axens Arabia is a global leader in advanced technologies and services for oil refining, petrochemicals, gas processing, and alternative fuels. Committed to innovation and sustainability, Axens provides comprehensive solutions to optimize operations and support the energy transition, making them a trusted partner in shaping the future of energy and the environment

Axens collaborated with The Disrupt Labs to develop the AI-powered Catalyst Inspection System to enhance accuracy, reduce manual effort, and improve operational efficiency. This innovative solution integrates machine vision cameras with real-time anomaly detection, allowing for automated inspections that minimize errors, reduce downtime, and improve production quality. By replacing manual inspections with AI-driven analysis, Axens has streamlined its quality control process, setting a new standard for efficiency in catalyst production.

The Challenge

Ensuring precise anomaly detection in catalyst production was a key challenge for Axens. The manual inspection process led to:

01.

Inconsistent Anomaly Detection

Variability in manual inspections resulted in defects going unnoticed, affecting overall quality.

02.

High Operational Costs

Labor-intensive inspections increased costs and slowed down production efficiency.

03.

Delayed Issue Identification

Without real-time monitoring, anomalies were detected late, causing unplanned downtime.

04.

Limited Production Insights

The lack of dynamic tracking made it difficult to analyze production trends and optimize processes.

“The AI-based PPE Monitoring System from The Disrupt Labs has transformed our approach to workplace safety. Automating PPE monitoring has minimized human error, brought compliance levels to over 95%, and saved us countless hours previously spent on manual tracking. The system’s intuitive dashboard and automated reporting allow our management team to make informed, data-driven decisions, significantly boosting both safety and operational efficiency. It has truly set a new benchmark for safety at our facility.”

M/S Axens

Representative

The Solution

To overcome these challenges, The Disrupt Labs developed an AI-driven Catalyst Inspection System that fully automates quality control.

Real-Time Monitoring

High resolution cameras capture images every 70 seconds, ensuring continuous inspection of catalyst production.

AI-powered anomaly Detection

The system identifies various complex defects reducing manual errors.

Automated Reporting & Alerts

Daily, weekly, and monthly email reports provide insights into defect frequency, time ranges, and live system data.

Integrated Data Storage

Inspection data is stored on cloud, categorized by Campaign ID and anomaly type for easy access.

User-Friendly Dashboard

Operators can view live camera feeds, machine status, and anomaly counts, enabling quick decisions and process adjustments.

The Outcome

The AI-powered Catalyst Inspection System has transformed Axens’ production operations, delivering measurable improvements:

90% Increase in Inspection Accuracy

AI-driven analysis eliminated human errors, ensuring defects were identified with greater precision.

25% Reduction in Downtime

Faster anomaly detection and automated alerts allowed for immediate corrective actions, minimizing production delays.

15% Cost Savings

Reduced reliance on manual inspections led to significant labor and operational cost reductions.

Improved Communication & Reporting

Automated email updates kept teams informed, streamlining issue resolution and improving collaboration.

Enhanced Decision-Making

Live monitoring and real-time insights empowered operators to optimize production efficiency dynamically.

Conclusion

The AI-powered Catalyst Inspection System has revolutionized quality control at Axens by making inspections faster, more accurate, and highly efficient. With real-time monitoring, automated defect detection, and detailed reporting, the system has minimized human errors, reduced downtime, and improved overall production quality. By adopting AI-driven automation, Axens has strengthened its manufacturing processes, ensuring consistent quality while lowering operational costs. This successful implementation highlights how advanced technology can optimize industrial production, setting a new standard for efficiency and reliability in the petrochemical sector.