Manufacturing leaders often face a stark choice: stick with proven but limited inspection systems, or undertake costly replacements to get advanced capabilities.
International Paper, however, recently demonstrated a different path—one that challenges conventional wisdom about modernizing quality control.
A Century-Old Manufacturer's Modern Challenge
With over 100 years of manufacturing excellence, International Paper's commitment to quality runs deep. Yet their facility faced a common challenge: an existing line scan system that, while reliable, required extensive manual intervention. Quality teams were spending countless hours reviewing potential defects, and high false-positive rates were leading to unnecessary waste.
Breaking the "Rip and Replace" Cycle
What happened next is interesting. Rather than undertaking a complete system overhaul, the facility took an innovative approach that preserved their existing infrastructure while adding sophisticated AI capabilities. The results were striking:
- Eliminated over 375,000 manual classifications annually
- Dramatically reduced false positives and material waste
- Achieved 100% defect traceability
- Completed implementation in one week
- Zero production disruption
Beyond the Numbers
But the story goes deeper than metrics. The facility's experience reveals important insights about modernizing manufacturing operations, challenging assumptions about what's possible with existing equipment, and navigating the path to AI-enhanced quality control.
Want the full story? Download our detailed case study to learn:
- The complete implementation process and timeline
- Specific ROI metrics and results
- Key lessons learned and best practices
- Future expansion plans
- How other manufacturers can apply these insights
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