An industrial components manufacturer
Catching defects at line speed
Edge-deployed computer vision that inspects every part on three production lines, reducing escaped defects and inspection fatigue.
- Defects reaching customers
- −45%
- Of parts inspected, up from sampling
- 100%
- Payback period
- 11 mo
The challenge
Quality inspection relied on operators examining a sample of parts under magnification. Accuracy varied by shift, and small surface defects were sometimes missed.
Customer returns were rising, and the manufacturer wanted to inspect every part without slowing the line.
Our approach
- 01
Data collection
Industrial cameras captured over 60,000 images, which quality engineers labelled using an efficient annotation workflow.
- 02
Model development
A detection model was trained and optimised to run in under 30 ms per part on edge hardware.
- 03
Line integration
Results feed directly into the line PLC to divert suspect parts automatically.
- 04
Continuous improvement
Operator overrides are captured and used in monthly retraining cycles.
Results
- Defects reaching customers fell by 45% in the first two quarters.
- Every part is now inspected, at full line speed.
- Operators were redeployed to root-cause analysis and process improvement.
“They were as comfortable on the factory floor as they were in a notebook. The system simply works, shift after shift.”
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Let’s build something that lasts.
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