Thanks to Maddox AI, a previously unstable inspection system was replaced with an AI-based solution that ensures reliable and continuous inspection of hoses after the extrusion process. By significantly reducing pseudo-scrap, manual effort, and recall actions, the cost efficiency of quality control was greatly improved.
Product
Industry
Total savings / year
Our customer manufactures wiper hoses using the extrusion process for automotive applications. Although the inspection process was already automated, the existing inspection system could not handle the high production variance, resulting in a pseudo-scrap rate of around 25%. In addition, a manual re-inspection by one specialist per shift was required three days a week. Despite these measures, regular product recalls occurred. The system also had to be recalibrated monthly for one week, causing additional downtime and high maintenance costs.
The goal of switching to the Maddox AI inspection system was to reliably detect defects such as foreign particles, scratches, and material breakouts so that customer complaints could be sustainably avoided and labor-intensive manual re-sorting eliminated.
Existing inspection system resulted in a pseudo-scrap rate of around 25%.
Pseudo-scrap reduced by 85% with Maddox AI.
1–2 recalls per month with several thousand euros in sorting costs.
No recalls or manual rework since installation of the new system.
Approx. 1 week of maintenance per month due to camera system recalibration.
No recalibration required and no downtime from the inspection system.
Existing inspection system resulted in a pseudo-scrap rate of around 25%.
1–2 recalls per month with several thousand euros in sorting costs.
Approx. 1 week of maintenance per month due to camera system recalibration.
Pseudo-scrap reduced by 85% with Maddox AI.
No recalls or manual rework since installation of the new system.
No recalibration required and no downtime from the inspection system.
Reduced pseudo-scrap
Customer complaints
Less maintenance effort
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