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Rooms / Industrial Machinery / Automated visual inspection, Line 4

Automated visual inspection, Line 4

Running in productionIndustrial MachineryComputer visionQualityRecorded March 2026
PR
Priya Raghavan
Plant Systems Lead / Ran this from kickoff to production
Status
In production
Since Nov 2025
Time to production
11 months
Two months over plan
Cost, fully loaded
$486K
Incl. internal time
Annual benefit
$1.2M
Scrap and rework
Team
5 people
2 full time
Reach
4 of 9 lines
Rollout continuing
Awaiting video01:38
CLIP 01 OF 12
What problem we were solving
Priya Raghavan, Plant Systems Lead
Problem
Key data from this clip
TRIGGER
Scrap rate ran 3.1% against a 1.5% target
Stated by owner
DETECTION POINT
End of line, by eye
Stated by owner
SHIFT VARIANCE
Different calls between Shift A and Shift B
Stated by owner

Everything asked, on camera

12 answers

What this was

Line 4 produces gearbox housings. Operators were catching surface defects by eye at the end of the line, which meant defects found late, high rework, and inconsistent calls between shifts. The team put cameras at two stations and trained a model to flag defects in real time.

It runs in production today on four of nine lines. The team is explicit that the first version failed under night-shift lighting and that fixing it cost seven weeks and $41,000, which is covered in clip 07.

Trigger
Scrap rate on Line 4 ran 3.1% against a 1.5% target
Approach
Built in house on an existing vision vendor's hardware
Measured by
Scrap, rework hours, and false-reject rate, verified against plant finance
Reusable
Yes, with retraining per part family. Two plants have copied it

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