Every year, more data cables are installed in a typical passenger vehicle. Cable failures are, by nature, highly critical. By upgrading the existing camera system with Maddox AI’s software, the visual quality control of data cables is enhanced with AI-powered defect detection, making it not only more precise but also more consistent.
Product
Industry
Total savings / year
Our customer manufactures millions of data cables for the automotive industry. In a three-shift operation, more than 20,000 parts are inspected daily — previously using a 360° camera system supplemented by manual X-ray inspections with four employees per shift. However, the initially installed inspection setup resulted in high scrap rates, customer complaints, and significant personnel requirements.
Maddox AI’s objective:
Optimize the existing inspection system to ensure that no defective parts reach the OEM while minimizing false rejects and reducing manual effort.
Combination of automated 360° camera inspection and manual X-ray image evaluation. Despite this double safeguard, customer complaints still occurred.
The existing camera system was intelligently upgraded with Maddox AI software, eliminating customer complaints entirely. The existing hardware was 100% reused.
Subjective defect evaluation led to high variability in inspection quality and complaints due to missed defects.
60% fewer false rejects and improved accuracy in defect classification.
Combination of automated 360° camera inspection and manual X-ray image evaluation. Despite this double safeguard, customer complaints still occurred.
Subjective defect evaluation led to high variability in inspection quality and complaints due to missed defects.
The existing camera system was intelligently upgraded with Maddox AI software, eliminating customer complaints entirely. The existing hardware was 100% reused.
60% fewer false rejects and improved accuracy in defect classification.
Cost for new hardware since existing hardware can be fully reused
Fewer false rejects
Inspected parts per day
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