Vision-based defect detection for a manufacturer. −72%.
defect escapes to customers. A custom computer-vision inspection system caught defects manual checks missed, cut escapes to customers, and freed inspectors for high-judgment work.
Book a Fusion WorkshopWhere the time was going.
Quality relied on human spot-checks and sampling. Inspectors were skilled but could not examine every unit at line speed, so subtle defects slipped through and reached customers as costly returns and reputation damage.
Sampling meant entire batches could ship with a recurring defect before anyone noticed the pattern.
The best inspectors were spending their time on repetitive visual checks rather than root-cause work.
What we shipped.
We built a custom vision system that inspects every unit at line speed and routes uncertain cases to people.
What changed.
Quality went from sampled to total.
Defect escapes to customers fell 72% because every unit is now inspected rather than a sample, and inspection throughput tripled. Recurring defects are caught as patterns early, and inspectors moved from repetitive checking to root-cause analysis.
“We went from checking samples to checking everything, and our inspectors finally work on why defects happen.”
Quality Manager, manufacturer
Built with, and what you own.
The manufacturer owns the trained model, the edge deployment, and the dashboards, integrated with their MES.
Line cameras·Custom vision model·Edge inference·MES integration·Dashboards
Questions about this build.
Will it slow the line?
No. Inference runs at the edge at line speed, so every unit is inspected without reducing throughput.
What about new or rare defects?
Borderline and novel cases route to an inspector, and their decisions retrain the model so coverage improves over time.
Other builds.
Cutting no-shows for a multi-location dental group·Capturing every after-hours call for an HVAC contractor·Sub-minute lead response for a real estate team·Scaling support without scaling headcount for an online retailer