This paper explains on the design and implementation of automatic visual inspection system in automatic control system based on Programmable Logic Controller (PLC). In addition, this paper also give solution on how to modify conventional PLC to be integrated with visual inspection system. This modification method is more efficient than buying a new PLC and enhances the ability of it. Integration of these systems is implemented in Modular Automation Production System (MAPS). MAPS is a miniature of real bottling system construct from some module which have different function but are integrated togather. Visual inspection is done by using low cost and common web cam camera. Every bottle image will be caugth by camera and then will be analysed using Real–TIVI program. There are three decisions taken based on the result. The first decision is to accept the bottle, if the size is appropriate with bottle ‘A’. The second decision is to accept if the size of bottle appropriate with bottle ‘B’. The last decision is to reject the bottle if the size is not appropriate. This decision then will be sent to PLC through dc hard wire cable. The testing of this system is done in Robotic Laboratory Faculty Information Science and Technology (FTSM) University Kebangsaan Malaysia (UKM). The result showed good performance from the system. The method used in this research can be implemented in other industries such as pharmacy and food and drink inspection