Vision QA System
Solution type: Manufacturing & Production
The Challenge
Manufacturers running visual quality inspection with human inspectors face well-documented limitations: eye fatigue after 90–120 minutes causes missed defects, throughput is capped by human speed, coverage is sample-based not 100%, and defects that escape to customers trigger costly recalls and warranty claims.
Our Solution
We deploy real-time computer vision systems across production lines — cameras at every quality gate, with custom-trained object detection models identifying defect types at production line speeds. 100% coverage, zero fatigue, automated rejection of non-conforming parts.
What We Built
- Design and install industrial camera arrays at critical inspection points along production lines
- Collect and label training images covering all defect types across varying lighting and orientation conditions
- Train and optimise YOLOv9 / custom vision models for edge deployment on NVIDIA Jetson devices at each station
- Build real-time alerting and automated rejection — defective parts trigger air ejectors automatically
- Create quality dashboards with live defect rates by line, shift, and defect type — integrating with ERP systems
Results: Before vs After
| Metric | Before | After | Change |
|---|---|---|---|
| Defect escape rate | 1.5–2% (human inspection) | < 0.1% | ↓ 90–95% |
| Inspection cost/shift | High (dedicated inspectors) | Near zero (automated) | ↓ 90%+ |
| Throughput speed | Human-limited | Full line speed | ↑ 40–60% |
| Coverage | Sample-based (~5%) | 100% of output | ↑ 20× coverage |
| Payback period | — | Typically 3–6 months | One recall avoided pays for it |
Timeline
Typically 10 weeks including hardware installation
Technologies
“Automated vision inspection eliminates the #1 source of quality escapes — human fatigue — and turns every camera on your line into a tireless, sub-millisecond quality decision-maker.”
What this means for your production line
Could this be your business?
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