By upgrading to the Maddox AI software, an Keyence existing camera system was significantly improved. Pseudo-scrap was drastically reduced, eliminating the need for manual re-inspections and increasing process reliability.
Product
Industry
Total savings / year
Our customer inspects primed car roofs in body construction. Although a camera-based visual inspection system from Keyence was already in place, it frequently produced pseudo-scrap. The rejected parts had to be laboriously rechecked manually, which significantly disrupted the production flow. Additionally, defective roofs had to be re-primed when necessary—a process that was highly time- and cost-intensive without a clear OK/NOK decision.
The goal was to enhance the existing inspection solution with more precise, AI-powered defect detection to improve both inspection quality and efficiency.
High pseudo-scrap rate from the existing Keyence camera system.
75% reduction in pseudo-scrap by upgrading the existing hardware with our AI-based software.
Manual re-inspection of rejected parts required due to pseudo-scrap issues.
No manual effort needed thanks to reduced pseudo-scrap.
Time- and cost-intensive re-primer processes.
More stable process chain with clear OK/NOK decision and traceability.
High pseudo-scrap rate from the existing Keyence camera system.
Manual re-inspection of rejected parts required due to pseudo-scrap issues.
Time- and cost-intensive re-primer processes.
75% reduction in pseudo-scrap by upgrading the existing hardware with our AI-based software.
No manual effort needed thanks to reduced pseudo-scrap.
More stable process chain with clear OK/NOK decision and traceability.
Less pseudo-scrap
Manual re-inspection effort
inspected parts per day
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