Surface defects such as rust, stains, or chipping can be reliably identified with Maddox AI. This not only reduces customer complaints but also enables targeted optimizations in the manufacturing process.
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Total savings / year
Our customer produces cast parts for industrial machinery, where even the smallest surface defects can cause functional or visual problems.
Manual visual inspection by employees is prone to error: good parts are rejected, and defective parts pass inspection — caused by production fluctuations and subjective evaluation. The result: scrap, additional costs, and customer complaints.
Goals: Automate visual inspection, achieve more consistent inspection quality, and use digital evaluations for process optimization.
Up to 9 employees per day were responsible for quality control, resulting in high manual effort and associated costs.
Quality inspection is now almost fully automated, significantly reducing manual effort and greatly increasing inspection efficiency.
High scrap rates and recurring customer complaints
| Thanks to the accuracy of the Maddox AI system, there have been no further customer complaints to date. |
No digital recording of defect data for process optimization
Maddox AI’s quality analyses help identify production patterns that cause defects at an early stage, thus reducing scrap.
The printed circuit boards were inspected manually in three shifts with a total of six employees. The detection accuracy varied depending on the inspector.
Due to the faulty assembly of printed circuit boards, the production was carried out with an excessively high reject rate.
Since the inspection results were not digitized, no regular structured root cause analysis was performed.
All products are inspected 100% automatically according to a precise defect definition. The inspection system is operated by one employee per shift.
Since installing Maddox AI, the scrap rate has been reduced by 25%.
Thanks to the digitalized inspection process, process optimizations could be realized (e.g. direct feedback loop for machine setting).
Digitized analyses
for retraining on new product types
Traceability for each individual component
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We are ISO 27001 certified.
