A zero-defect quality line
a tier-one automotive supplier
less scrap
defect detection rate
escapes to the customer line
Visual inspection relied on tired human eyes at line speed, so subtle defects slipped through while good parts got scrapped. Quality varied by shift and inspector. Scrap and warranty costs mounted, and a single missed defect could halt a customer's line. The supplier needed consistent, defensible inspection at production pace.
How we approached it
Collected and labeled defect images across product lines and shift conditions.
Built a vision model to detect defects in real time and explain each rejection.
Integrated with line controls to flag and divert suspect parts automatically.
Ran the model alongside inspectors first, comparing calls before handing it the line.
“Quality no longer depends on which inspector is on shift. The line catches what eyes miss and tells us exactly why a part failed.”
Consistent vision inspection catches subtle defects human eyes miss while sparing good parts that were previously scrapped out of caution, cutting both error directions.
It ran in parallel with human inspectors first, and its calls were compared against theirs until detection performance was proven before it took over inspection.
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