Optimization of Brake Hose inspection

Surface Inspection

Maddox AI can efficiently and reliably automate the inspection of surface defects, such as scratches, burns, or stripping cuts.

product

Brake Hose

industry

Automotive

total savings year

90-120k €

Kundenanforderung

Our customer produces over 70,000 meters of brake hoses every day, which were inspected both by an automated vision system and manually by employees. The existing inspection system often detected defects that were not actually defects, such as slight surface defects or color deviations. This led to a pseudo reject rate of around 5%. In addition, there were several customer complaints, which led to cost-intensive manual re-sorting actions.
To significantly reduce the pseudo reject rate and slippage, the Maddox AI inspection system combines the existing camera hardware with the Maddox AI software. Common defect types that are detected include surface defects such as scratches, cuts and other damage from previous production steps.

before

Previous Inspection System

after

With Maddox AI

The quality of the brake hoses was previously monitored by an automated vision system and manual checks in three shifts, with one to two employees per shift.

Thanks to the integration of the Maddox AI system, quality inspection is fully automated, eliminating the need for manual inspectors. This enables more efficient and precise inspection around the clock.

On average, around 10% of the parts produced were classified as faulty, with half of the parts declared as faulty being pseudo rejects.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 85%, virtually eliminating re-inspections and avoiding unnecessary costs.

Due to the inadequate accuracy of the system, weekly manual re-sorting operations were required, during which the parts had to be checked and re-checked.

Maddox AI has completely eliminated the need for manual re-sorting, as the system accurately and reliably distinguishes between good and faulty parts.

85 %

Reduced pseudo scrap

> 90 %

Time savings on recalibrations

50 m / min

Inspection speed

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