Production Line Quality Inspection
99.2% detection accuracy
Client Context
An automotive parts manufacturer running 12 production lines producing 150 parts per minute. Quality inspection was performed by trained human inspectors at the end of each line.
The Challenge
Human inspectors achieved 87% defect detection accuracy, but fatigue, shift changes, and subjective judgement led to inconsistent quality. Defective parts reaching customers resulted in costly returns and damaged relationships with tier-1 automotive OEMs.
Our Approach
We deployed computer vision systems on all 12 production lines using high-speed cameras and YOLO26 models trained on the manufacturer’s specific part geometries and defect types. The system detects defects at line speed with real-time rejection, logging every inspection for quality traceability.
Timeline: 18 weeks
The Results
- 99.2% detection accuracy vs 87% human
- Scrap rate reduced 34%
- Customer returns reduced 61%
- 100% inspection coverage (vs sampling by human inspectors)
- Full quality traceability for automotive compliance
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