Manufacturing Quality Control with Vision AI
Implemented computer vision system detecting defects with 99.5% accuracy, reducing waste by 35%.
Detection Rate
Accuracy
Waste Reduction
Material savings
Throughput
Inspection speed
Returns
Customer complaints
!The Challenge
A precision electronics manufacturer faced quality control challenges on their production line. Human inspectors could only catch 85% of defects, and inspection became a bottleneck.
Critical issues: - 15% defect escape rate to customers - Inspection speed limiting production capacity - Inconsistent quality standards across shifts - High cost of warranty claims and returns - Difficulty training new inspectors
Our Solution
We deployed an edge-based Vision AI system for real-time defect detection directly on the production line.
Vision AI System
- High-speed cameras capturing 60 frames/second - Custom CNN models trained on 50,000+ defect images - Edge computing for <100ms inference latency - Multi-defect detection (scratches, misalignment, solder issues)
Integration with Production
- Automatic reject mechanism for defective units - Real-time dashboards for line supervisors - Shift-wise quality reports - Trend analysis for process improvement
Continuous Improvement
- Active learning from new defect types - A/B testing of model versions - Correlation with production parameters
Vision AI Inspection Pipeline • Click to enlarge
Results & Impact
Technologies Used
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