Maddox AI enables the reliable automation of surface inspections for metal objects, accurately detecting defects such as scratches and dents.
Product
Industry
Total savings / year
Our client produces up to 15,000 gears daily, which were previously inspected manually by three employees per shift, operating in a three-shift system, five days a week. This entirely manual process was both time-consuming and costly. To increase efficiency and reduce inspection costs, the Maddox AI inspection system was implemented.
A specialized camera hardware solution was developed for this customer, working seamlessly with the powerful Maddox AI software. Together, they accurately detect surface defects like scratches and dents. This significantly reduces the manual inspection effort while improving accuracy in identifying real defects. The result? Significant cost savings and optimized quality assurance.
The gears were previously inspected manually across three shifts, involving up to nine employees in total. The accuracy of defect detection varied significantly depending on the individual, leading to inconsistent results.
Now, all products are inspected 100% automatically using a clearly defined set of defect criteria. Only one employee per shift is required to operate the system.
On average, the plant received two customer complaints annually, which required manual reinspection.
Since the implementation of Maddox AI, there have been no customer complaints.
Before, inspection results were not recorded digitally, so there was no structured root cause analysis for defective (NOK) parts.
With the digitized inspection process, the scrap rate in production has been reduced by 20%.
The gears were previously inspected manually across three shifts, involving up to nine employees in total. The accuracy of defect detection varied significantly depending on the individual, leading to inconsistent results.
On average, the plant received two customer complaints annually, which required manual reinspection.
Before, inspection results were not recorded digitally, so there was no structured root cause analysis for defective (NOK) parts.
Now, all products are inspected 100% automatically using a clearly defined set of defect criteria. Only one employee per shift is required to operate the system.
Since the implementation of Maddox AI, there have been no customer complaints.
With the digitized inspection process, the scrap rate in production has been reduced by 20%.
Traceability for each component
Digitized analyses
Reduced manual effort
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