Thanks to Maddox AI, even the smallest defects in seals, pins, or plastic coatings of complex plastic–metal components can be reliably and automatically detected.
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Our customer produces more than 20,000 connectors per day across multiple production lines. Typical defects include inclusions in silicone seals, bent pins, incomplete overmolding, foreign particles, burrs, and rough surfaces.
The customer approached us with two major pain points:
Quality control had previously been performed through a combination of automated top-down inspection and manual visual checks under a magnifying glass by a sorting service provider. This process was labor-intensive and prone to error.
The startup process of the injection molding machines resulted in initially high scrap rates. The subsequent adjustment process took too long, leading to a significant number of parts being scrapped and causing high follow-up costs.
To meet growing production volumes while reducing scrap costs and customer complaints, the company decided to fully automate inspection with Maddox AI.
Three to six employees per day were required for quality control, resulting in high manual effort and associated costs.
Quality control is now fully automated, drastically reducing manual work and significantly increasing inspection efficiency.
Up to 15% of produced parts were classified as defective, with a significant share being false rejects.
85% fewer false rejects thanks to reliable and objective inspection.
The complex startup process of the injection molding machines caused scrap costs of more than €5,000 per month.
Smart analytics (defect heatmaps, alerting, dashboards) identified the root cause in the startup process, reducing scrap costs by more than 90%.
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).
Less manual effort
Fewer false rejects
Reduction in scrap through process improvements
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