Inspection of Printed Circuit Boards

Surface Inspection, Component Recognition and Data Matrix Code Recognition

Inspection of Printed Circuit Boards

Thanks to Maddox AI’s device and software, incorrectly assembled components and other damages can be detected and tracked to a specific PCB.

Product

Printed Circuit Boards

Industry

Electronics

Total savings / year

110-160k €

Customer Request

Our customer manufactures printed circuit boards, which were manually inspected by two people in a three-shift operation due to the variety and complexity of the production. A classic inspection system was already used to check individual components – but a hundred percent automated end-of-line inspection did not happen, yet.

Maddox AI has developed a semi-automatic inspection system in which printed circuit boards are inspected with a high-resolution camera. Due to the high product variability, a fully automated inspection system was not possible. The system is used to detect, among other things, defectively mounted components and other damages such as scratches, or solder bumps. By reading a data matrix code, the Maddox AI system tracks defects to a specific component. In the first step, the system is loaded manually. New defect classes have already been retrained several times free of charge.

Before

Previous Inspection System

After

With Maddox AI

The printed circuit boards were inspected manually in three shifts with a total of six employees. The detection accuracy varied depending on the inspector.

All products are inspected 100% automatically according to a precise defect definition. The inspection system is operated by one employee per shift.

Due to the faulty assembly of printed circuit boards, the production was carried out with an excessively high reject rate.

Since installing Maddox AI, the scrap rate has been reduced by 25%.

Since the inspection results were not digitized, no regular structured root cause analysis was performed.

Thanks to the digitalized inspection process, process optimizations could be realized (e.g. direct feedback loop for machine setting).

Before

Previous Inspection System

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.

After

With Maddox AI

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).

0€ costs

For expansion to further product variants

100%

Tracability by reading the data matrix code

40%

less pseudo scrap

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Cosmetic Container Inspection

Maddox AI’s software, as well as the implementation of three individual camera systems, can reliably inspect surfaces, labels and imprints.

Inspection of E-Modules

Maddox AI enables the reliable and automated identification of defects such as sheet metal damage, bubbles in the potting, damaged conductor paths and many more.

Optimization of Brake Hose inspection

Fully automated Wire Inspection

Surface Inspection

Fully automated Wire Inspection

Surface defects such as dents, burnt spots, or insulation faults can be reliably and automatically checked using Maddox AI.

Product

Wire

Industry

Energy Technology

Total savings / year

360-650k €

Customer Request

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.

Before

Previous Inspection System

After

With Maddox AI

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.

Before

Previous Inspection System

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.

After

With Maddox AI

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.

100%

Digitized analyses

MES Integration

Enables the use of data for process improvements

180 Images / Second

Inspection speed

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Inspection of Medical Syringes

Surface defects such as impurities, burrs and cracks on tips of syringes can now be reliably checked automatically with the help of Maddox AI.

Gear Inspection

Maddox AI enables the reliable automation of surface inspections for metal objects, accurately detecting defects such as scratches and dents.

Inspection Cell for Plastic Seals

By integrating a rotating inspection cell with three cameras in combination with Maddox AI’s software, the plastic seals are reliably inspected 100% of the time.

Wire Cable Inspection

Surface Inspection

Wire Cable Inspection

Maddox AI’s consistent, fully automated 100% quality inspection reliably detects defects such as wire breaks, knots, corrosion and many other types of defect.

Product

Wire Cable

Industry

Infrastructure

Total savings / year

40 - 50k €

Customer Requirements

Our customer produces many kilometers of wire every day, which are then wound into ropes. The quality control of these safety-critical components is carried out both by installed cameras and by two employees who manually inspect the recorded images again and examine them for defects. The inspectors’ fluctuating inspection accuracy led to both customer complaints and increased scrap costs due to pseudo rejects. The Maddox AI system ensures that no defects are overlooked and that a consistent inspection performance is achieved at all times.

Before

Previous Inspection System

After

With Maddox AI

The quality check is now fully automated, which has significantly reduced the manual effort and considerably increased the efficiency of the checks.

On average, only 50% of the rejected parts were really faulty. 50% of the parts could still be sold without any problems.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 65%, thereby avoiding unnecessary costs.

On average, only 20% of the rejected parts were really faulty. 80% of the parts could still be sold without any problems / with minor reworking.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 75%, virtually eliminating re-inspections and avoiding unnecessary costs.

Before

Previous Inspection System

The quality check is now fully automated, which has significantly reduced the manual effort and considerably increased the efficiency of the checks.

On average, only 50% of the rejected parts were really faulty. 50% of the parts could still be sold without any problems.

On average, only 20% of the rejected parts were really faulty. 80% of the parts could still be sold without any problems / with minor reworking.

After

With Maddox AI

The quality check is now fully automated, which has significantly reduced the manual effort and considerably increased the efficiency of the checks.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 65%, thereby avoiding unnecessary costs.

Thanks to the increased precision of the Maddox AI inspection system, the pseudo reject rate has been reduced by around 75%, virtually eliminating re-inspections and avoiding unnecessary costs.

100%

Digitized Analyses

0 € Costs

for the extension to further error classes

20 Months

Investment Payback Period

Would you like to learn more about our solution? – Test for free now!

Inspection of Ball Bearings

Maddox AI successfully automates the inspection of impact points, incorrectly mounted components and scratches on ball bearings.

Inspection of Injection Molded Parts

Surface defects such as improper cutting edges, cracks, scratches, and contamination can be reliably and automatically identified on injection-molded parts with the help of Maddox AI.