By integrating Maddox AI into the existing camera system, manual re-inspection of laser bars is significantly reduced, while detection quality is improved and the OK/NOK evaluation is standardized.
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Total savings / year
Our customer produces highly sensitive laser bars in a 24/7 three-shift operation. Quality control was previously carried out through automatic image capture followed by manual evaluation by trained experts. Per shift, one specialist reviewed over 10,000 images from a single batch. The defect rate fluctuated significantly, between 2% and 20%, depending on individual assessment.
The goal was to automate image inspection in order to reduce re-inspection, ease the workload of employees, and make evaluations more objective.
Quality control was carried out manually, resulting in significant time expenditure and high costs.
Thanks to Maddox AI’s fully automated inspection system, all laser bars are inspected efficiently, with defects detected precisely and reliably.
Detection accuracy varied depending on the inspector. Subjective assessment led to large fluctuations in defect rates (2–20%).
With the increased precision of Maddox AI’s inspection system, the false reject rate was significantly reduced, avoiding unnecessary costs.
High personnel effort for re-inspections of rejected bars.
Reduction of re-inspection for rejected bars by 60–90%.
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 re-inspection
Reduced manual effort
Digitized analyses
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