Surface defects such as dents, burnt spots, or insulation faults can be reliably and automatically checked using Maddox AI.
Product
Industry
Total savings / year
Our customer manufactures transformers where various wire elements are wound at high speeds. The winding systems sometimes operate at over 10 meters per second, making a 100% manual inspection impossible. If a transformer is wound incorrectly, it can lead to complete failure, resulting in significant costs.
Maddox AI has developed a smart camera device that uses mirrors to monitor 100% of the wire’s surface area. This device detects issues such as discoloration, burn marks, and insulation faults.
It was manually checked in three shifts by an employee on a sample basis. The detection accuracy varied depending on the inspector.
All products are 100% automatically inspected according to a precise defect book definition, resulting in reduced scrap.
The plant received an average of 1-3 customer complaints per year, which had to be manually rechecked.
Since the installation of Maddox AI, no further customer complaints have been received.
Since the inspection results were not digitized, no structured root cause analysis was conducted for the production of non-conforming (NOK) parts.
Thanks to the digitized inspection process, several process optimizations, such as supplier management, have been implemented.
It was manually checked in three shifts by an employee on a sample basis. The detection accuracy varied depending on the inspector.
The plant received an average of 1-3 customer complaints per year, which had to be manually rechecked.
Since the inspection results were not digitized, no structured root cause analysis was conducted for the production of non-conforming (NOK) parts.
All products are 100% automatically inspected according to a precise defect book definition, resulting in reduced scrap.
Since the installation of Maddox AI, no further customer complaints have been received.
Thanks to the digitized inspection process, several process optimizations, such as supplier management, have been implemented.
Digitized analyses
Enables the use of data for process improvements
Inspection speed
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We are ISO 27001 certified.
