The problem
A precision components manufacturer relies on human inspectors performing 100% visual inspection of machined parts. Inspectors fatigue after 2-3 hours, miss rate climbs to 5-8% by end of shift, and throughput is capped at 400 parts/hour per station. Escaped defects generate warranty claims averaging $18K each.
94% reduction in escaped defects; 3x inspection throughput
- How it works
- High-resolution line-scan cameras capture every part at full line speed. The processing layer normalizes lighting and orientation. A fine-tuned object detection model identifies surface defects (scratches, porosity, burrs) and dimensional anomalies. Parts flagged as defective are diverted automatically. Borderline detections (confidence 70-90%) route to a human reviewer who validates with a single click, and that feedback retrains the model weekly.
- Outcome
- Defect escape rate reduced from 5-8% to 0.3%. Inspection throughput increased to 1,200 parts/hour. Two of four inspection stations redeployed to higher-value quality engineering work.