AI Visual Inspection System

Leveraging deep learning, real-time image capture, and data governance, we assist the manufacturing industry in establishing multi-scenario automated visual inspection processes, improving defect detection rates, shortening inspection cycle times, and enhancing traceability.

Solution Overview

We help clients integrate production processes, visual sensing, and backend quality systems to build AI visual recognition services capable of real-time feedback.

Architecture

• Edge devices handle image collection and pre-processing, transmitting inference results via high-speed networks.
• An AI model platform centralizes training, deployment, and version management, supporting synchronized upgrades across multiple production lines.
• Visual interpretation results are integrated with MES, QMS, ERP, and other systems to form a traceable quality closed loop.

Benefits

• Defect detection rate improved by over 30%, significantly reducing human error.
• Digital labels and image evidence create queryable production history and statistical reports.
• Continuous model learning adapts to new products, low-volume high-mix, or highly complex inspection scenarios.

Implementation Process

Based on production takt time and inspection specifications, we define data governance and model iteration processes to ensure AI models are tightly integrated with on-site SOPs.

Data Governance

• Establish standardized sample collection specifications (shooting angle, lighting, targets).
• Use semi-automated annotation tools for defect classification, bounding, and segmentation.
• Manage samples by batch, process, and equipment version for easy tracking and backtracking.

Model Training & Deployment

• Adopt architectures like CNN / Transformer for multi-task training.
• Complete model testing, deployment, and monitoring via MLOps processes.
• Establish feedback mechanisms: on-site personnel can return misjudged samples to continuously optimize the model.

Core Features

The system focuses on automated inspection, result visualization, and data-driven quality analysis, supporting real-time production line response and management decision-making.

Real-time Inspection

• High FPS image streaming supports synchronous inspection and segmented interpretation.
• Defect classification, positioning, dimension measurement, and severity scoring.
• Supports Optical Character Recognition (OCR) and serial number tracking to prevent material errors.

Visualization & Reports

• Dashboards present NG/OK trends, Top Defects, and equipment utilization rates.
• Every inspection retains images and interpretation data for QA/IE tracking.
• Integration with SPC and quality indicators supports process improvement decisions.

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