Computer Vision Quality Control

An AI-powered visual inspection system that detects manufacturing defects in real-time, replacing manual inspection with consistent, accurate automation.

The Challenge

An electronics manufacturer struggled with quality control:

• Human fatigue - Inspectors missing defects after hours
• Inconsistency - Different inspectors, different results
• Speed bottleneck - Inspection slowing production
• High scrap rate - Defects caught too late in process

They needed automated, consistent inspection.

Our Approach

We built an edge AI system that inspects products at production speed.

Technical Strategy

1. Edge Processing - Real-time inference on production line
2. Transfer Learning - Quick training on new defect types
3. Human-in-Loop - Easy labeling for continuous improvement
4. Line Integration - Minimal disruption to production

The Solution

Image Capture

• High-resolution industrial cameras
• Lighting optimization
• Multiple angle capture
• Conveyor synchronization

Defect Detection

• Surface defect recognition
• Dimensional verification
• Color and finish inspection
• Assembly verification

Edge Inference

• NVIDIA Jetson deployment
• Sub-50ms inference time
• Multiple cameras per edge device
• Fail-safe operation

Quality Dashboard

• Real-time defect metrics
• Trend analysis
• Shift comparisons
• Defect image archive

Technology Stack

Results & Impact

The system transformed quality operations:

• 99.5% accuracy in defect detection
• 90% reduction in manual inspection labor
• 10x faster than human inspection
• 6-month ROI on implementation

AI Features

Defect Types Detected

• Scratches and surface marks
• Cracks and chips
• Missing components
• Misalignment and gaps

Continuous Learning

• Easy image labeling interface
• Automated retraining pipeline
• A/B testing of models
• Performance monitoring

Client Testimonial

"We eliminated quality escapes to customers and reduced our inspection labor by 90%. The system catches defects human eyes would miss every time."

— Quality Director, Electronics Manufacturer

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Automating quality control? Contact us to discuss computer vision solutions.