Optimization of Wire Cable Inspection

Upgrading to Maddox AI Software optimized the existing camera system to the point that manual re-inspections became unnecessary. Maddox AI’s consistent, fully automated 100% quality inspection reliably detects defects such as wire breaks, knots, corrosion and many other types of defects.

Product

Wire Cable

Industry

Automotive

Total savings / year

40 - 50k €

Large spools of steel cable in an industrial warehouse.

Customer Request

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

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.

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.

100%

Digitized analyses

0 € Costs

For the extension to further error classes

20 Months

Investment payback period

Want to learn more about our solution?

Try it free now!

Book a demo

Want to learn more about our solution?

Try it free now!

Book a demo

Want to learn more about our solution?

Try it free now!

Book a demo

Bundles of galvanized steel pipes stacked on pallets outside a factory warehouse.

Inspection of Drain Pipes

Maddox AI enables complete weld seam inspection on rainwater downpipes without having to rotate the component. This transforms the previously sample-based inspection into an efficient, automated process with high defect detection rates and significantly reduced personnel requirements.

Industry & Infrastructure

To Success Story

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

Retrofit

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.

Electronics

To Success Story