Product

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Resources

Company

Surface Inspection, Retrofit

Optimization of Primer Inspection on Car Roofs

Optimization of Primer Inspection on Car Roofs

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

Product

Car Roofs

Industry

Industry

Automotive

Total savings / year​

Total savings / year​

90-120k €

White sedan with a highlighted rear window area.

Customer Request

Customer Request

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.

Before

Before

Previous Inspection System

Previous Inspection System

Previous Inspection System

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.

After

After

With Maddox AI

With Maddox AI

With Maddox AI

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.

No manual effort needed thanks to reduced pseudo-scrap.

More stable process chain with clear OK/NOK decision and traceability.

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.

75%

75%

75%

Less pseudo-scrap

0

0

0

Manual re-inspection effort

1.500

1.500

1.500

Inspected parts per day

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Would you like to learn more about our solution?

Try it now for free!

Would you like to learn more about our solution?

Try it now for free!