By upgrading an existing Keyence vision system with Maddox AI, the quality inspection was taken to a new level. Thanks to Maddox AI, even the smallest defects in seals, pins, or plastic coatings of complex plastic–metal components can be reliably identified. The significant reduction in false rejects eliminated the need for manual re-inspections.
Product
Industry
Total savings / year
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 inspection previously relied on a combination of automated top-view inspection using a Keyence vision system and subsequent manual visual checks under a magnifying glass performed by an external sorting service provider. This approach was highly labor-dependent, time-consuming, and therefore prone to errors.
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.
Since the Keyence system alone was not sufficient, three to six employees were required each day for quality inspection, resulting in a high level of 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%.
Since the Keyence system alone was not sufficient, three to six employees were required each day for quality inspection, resulting in a high level of manual effort and associated costs.
Up to 15% of produced parts were classified as defective, with a significant share being false rejects.
The complex startup process of the injection molding machines caused scrap costs of more than €5,000 per month.
Quality control is now fully automated, drastically reducing manual work and significantly increasing inspection efficiency.
85% fewer false rejects thanks to reliable and objective inspection.
Smart analytics (defect heatmaps, alerting, dashboards) identified the root cause in the startup process, reducing scrap costs by more than 90%.
Less manual effort
Fewer false rejects
Reduction in scrap through process improvements
Would you like to learn more about our solution? – Test for free now!
We are ISO 27001 certified.
