AI-Powered Quality Control for Precision Manufacturing
The Challenge
Manual quality inspection was creating bottlenecks, with a 3.2% defect rate slipping through to customers and costing €180k annually in returns and rework.
Our Solution
Designed and deployed a computer vision inspection system integrated directly into the production line, with real-time defect detection and automated routing of flagged units.
Results
87%
Defect Rate Reduction
Defect pass-through rate dropped from 3.2% to 0.4% within the first month of deployment.
€156k
Annual Cost Savings
Eliminated the majority of return and rework costs, with additional savings from reduced manual inspection hours.
3x
Inspection Speed
Throughput increased threefold with automated inspection replacing manual spot checks.
Strategic Impact
The quality data generated by the AI system now informs upstream process improvements, creating a continuous optimisation loop that extends well beyond defect detection.
“We expected a quality tool. What we got was a system that fundamentally changed how we think about our production process.”