The challenge
Manual visual inspection could not keep pace with line speed, and defect escapes were damaging relationships with key customers. Off-the-shelf vision tools struggled with the manufacturer’s specific parts and lighting conditions.
What we did
- We built a labelled dataset from the manufacturer’s own images and historical defect records.
- Custom vision models were trained and evaluated for each defect class, then optimised to run at the edge on existing line hardware.
- An inspection agent logs every decision with images, so quality engineers can audit and retrain.
- DigiEx operates the models 24/7, monitoring drift and retraining as products change.
The outcome
Defect escapes fell by 42%, inspection throughput tripled, and the solution scaled from one pilot line to multiple lines in eight weeks.
