With Maddox AI, the labor-intensive manual visual inspection of punched parts is replaced by a scalable, AI-powered solution that delivers reliable results, reduces complaints, and enables significant personnel savings.
Product
Industry
Total savings / year
Our customer manufactures over 50 variants of highly complex punched parts for safety-critical applications. Quality control was still performed entirely manually. Up to 30 employees inspected around 2,400 components per day under a microscope. Despite their experience, misclassifications occurred regularly: good parts were rejected, and defective parts were passed as OK.
The result: customer complaints, re-sorting actions, and high internal costs.
The goal was a fully automated solution that could be seamlessly integrated into the existing handling system while delivering maximum precision.
Manual inspection under a microscope by up to 30 employees in 24/7 operation
Fully automated 100% quality inspection on multiple pilot lines using a flexible and mobile system
Manual inspection resulted in increased pseudo-scrap, undetected defects, and ultimately customer complaints
Zero customer complaints on these lines thanks to reliable AI-powered defect detection
Enormous personnel and process costs combined with high quality risks
Significant cost savings through automation and reduced scrap, rework, and complaints
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).
Mobile inspection system for complete flexibility
Customer complaints
Automated inspection
Would you like to learn more about our solution? – Test for free now!
We are ISO 27001 certified.
