Upgrading to Maddox AI Software made the existing Keyence camera system significantly more powerful: daily recalibration is no longer required, pseudo scrap was reduced substantially, and scrap as well as re-sorting costs were noticeably lowered. At the same time, the fully automated 100% quality inspection reliably detected defects across more than 50 product types.
Product
Industry
Total savings / year
Our customer produces filters in various designs in a 3-shift operation. Quality control was previously carried out using a rule-based camera system. However, due to the diversity of production, the existing Keyence camera system had to be recalibrated daily in order to limit the pseudo reject rate. Despite the regular recalibration of the camera system, the old camera control led to a pseudo reject rate of up to 80%, which in turn led to high scrap / re-sorting costs.
With the introduction of Maddox AI, the inspection system only needs to be recalibrated / retrained in a few cases and the average pseudo reject rate has been reduced by over 90%. Defective filters are now reliably rejected, while OK filters are reliably classified as OK even with different production batches.
The existing Keyence inspection system had to be recalibrated several times a day.
Thanks to Maddox AI Software, the inspection system no longer requires recalibration and can reliably handle different product types.
Depending on the product type / batch, up to 80% of the filters were classified as NOK, although the majority of these were OK parts.
Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 90%.
New product types had to be laboriously stored individually in the inspection software.
New filter types are automatically and reliably inspected by the Maddox AI software.
The existing Keyence inspection system had to be recalibrated several times a day.
Depending on the product type / batch, up to 80% of the filters were classified as NOK, although the majority of these were OK parts.
New product types had to be laboriously stored individually in the inspection software.
The inspection system no longer needs to be recalibrated thanks to the Maddox AI software and can reliably handle different product types.
Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 90%.
New filter types are automatically and reliably inspected by the Maddox AI software.
Reduced recalibration time
Reduced pseudo rejects
Inspected product variants on a line
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