Real-Time Defect Detection with AI Integration

Overview

A manufacturing client relied on outdated manual visual inspection for quality control. This process was slow and prone to human errors. Customers sometimes received defective products, which resulted in dissatisfaction.

They reached out to Digital is Simple for assistance. Through our AI integration services, we built a computer vision system that automatically scanned products. This new system could detect defects in real-time and allow for quick intervention.

Industry

Manufacturing

Services

AI Integration

Our Process

–

1
Requirement Analysis

We worked closely with the client’s quality team to catalogue all kinds of defects.

2
Model Training

We collected thousands of images of approved and defective pieces to train the new system.

3
Hardware Integration

We chose and installed suitable industrial cameras and lighting on the assembly line. Then thoroughly tested and calibrated them on-site.

4
Deployment and Feedback

The system was deployed and configured at the same time. We had to establish a process where new defect types were identified and fed into the system.

Problems Our Client Faced

· Inconsistent quality checks

· High rate of product returns

· Lack of quality assurance processes.

Our Role

  • Integration AI with existing systems
  • Creating feedback loops
  • Sourced and added necessary hardware

Project Challenges

Adapting to Variable Changes

Ensuring the system correctly identified detects in different lighting conditions was tough.

Recognizing Complex Defects

We had to train the model to detect complex and non-obvious flaws in different products.

Minimizing Disruptions

Integrating AI with old factory equipment required careful planning and gradual implementation to avoid downtime.

Results We Saw

· 90% accuracy in defect detection

· 55% reduction in product returns

· 20% decrease in material waste.