By upgrading to the Maddox AI software, an 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 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 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
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 pseudo-scrap
Manual re-inspection effort
inspected parts per day
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