Product

Industries

Resources

Company

Surface Inspection, Retrofit

Optimization of Data Cable Inspection

Optimization of Data Cable Inspection

By upgrading the existing camera system with Maddox AI’s software, the visual quality control of data cables is enhanced with AI-powered defect detection, making it not only more precise but also more consistent.

Product

Product

Data Cables

Industry

Industry

Automotive

Total savings / year​

Total savings / year​

90-120k €

Bundles of cables bound together with cable ties, in a close-up.

Customer Request

Customer Request

Our customer manufactures millions of data cables for the automotive industry. In a three-shift operation, more than 20,000 parts are inspected daily — previously using a 360° camera system supplemented by manual X-ray inspections with four employees per shift. However, the initially installed inspection setup resulted in high scrap rates, customer complaints, and significant personnel requirements. Maddox AI’s objective: Optimize the existing inspection system to ensure that no defective parts reach the OEM while minimizing false rejects and reducing manual effort.

Before

Before

Previous Inspection System

Previous Inspection System

Previous Inspection System

Combination of automated 360° camera inspection and manual X-ray image evaluation. Despite this double safeguard, customer complaints still occurred.

Subjective defect evaluation led to high variability in inspection quality and complaints due to missed defects.

After

After

With Maddox AI

With Maddox AI

With Maddox AI

Combination of automated 360° camera inspection and manual X-ray image evaluation. Despite this double safeguard, customer complaints still occurred.

The existing camera system was intelligently upgraded with Maddox AI software, eliminating customer complaints entirely. The existing hardware was 100% reused.

60% fewer false rejects and improved accuracy in defect classification.

Subjective defect evaluation led to high variability in inspection quality and complaints due to missed defects.

60% fewer false rejects and improved accuracy in defect classification.

€ 0

€ 0

€ 0

Cost for new hardware since existing hardware can be fully reused

60%

60%

60%

Fewer false rejects

>20,000

>20,000

>20,000

Inspected parts per day

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Want to learn more about our solution?

Try it free now!

Want to learn more about our solution?

Try it free now!