Machine Vision QC
Manual inspection at line speed was statistically incapable of catching the defect types European buyers were rejecting shipments for.
- Timeline
- 90 day phased deployment: hardware installation and initial model training in weeks 1, 6, supervised parallel running (manual + machine vision) in weeks 7, 10, full production handover with threshold tuning in weeks 11, 12.
- Scope
- Full deployment scoping, camera and sensor selection calibrated to line geometry and defect taxonomy, CNN training on client owned defect image archive, integration with existing production line controls, documentation output configuration to EN standard requirements, operator training and threshold calibration support.
- Model
- On site commissioning team with production engineering involvement at every stage. Threshold sensitivity and defect classification reviewed jointly with quality managers before go live. Post deployment model retraining protocol established using flagged borderline cases, the system improves with production volume.
The outcome
Customer claims fell from 4.2% to 0.7% of shipped volume; investment recovered in 14 months from claims reduction alone.
Findings
What we built it around.
Dual high speed line scan cameras with full web coverage (4.4m width)
GPU based defect detection processor with CNN trained on proprietary defect image library
Beta gauge cross web sensor array for real time gramage deviation detection
Configurable defect density threshold logic with automatic roll flagging
Per roll automated quality documentation output (defect map, weight profile, dimensional measurement)
EN aligned quality record generation for EU buyer compliance
Results
What changed.
Defect detection rate improved from ~45% (manual inspection) to 91% (machine vision) within 90 days of deployment
Customer claims fell from 4
2% to 0.7% of shipped volume, an 83% reduction, with claims reduction alone recovering the full system investment in 14 months
Production line speed subsequently increased by 15%, previously constrained by manual inspection throughput
Automated per roll quality documentation became a commercial differentiator with EU buyers requiring EN standard quality records, enabling access to specification grade tender positions previously unavailable
Takeaway
Customer claims fell from 4.2% to 0.7% of shipped volume; investment recovered in 14 months from claims reduction alone.
Manufacturing
Start a discovery
Most engagements begin with a conversation about context.
We do not send a proposal before we understand the problem. Start by telling us about your decision context. We will identify the highest leverage intervention areas before any scope is agreed.