Real-Time Quality Control with Computer Vision and Edge AI

Introduction

A large FMCG (Fast-Moving Consumer Goods) manufacturer aimed to enhance production line quality control by implementing automated quality checks directly on the line. Real-time detection was crucial for effective quality control, as delays in finding defects would increase waste, reduce production efficiency and impact profits.

Solution for Real-Time Quality Control

Darwin Edge and the Bonseyes consortium created a Deep Learning-based Computer Vision model specifically designed for detecting and categorizing defects in real time. This solution helped the manufacturer improve production speed, reduce waste, raise product quality and ultimately improve profitability. Optimized for Edge AI, the model operates directly on production line machines without relying on cloud connectivity, ensuring no latency. This setup allows immediate defect detection and real-time alerts, enabling operators to respond quickly.

Technology Stack

We used a DigiFlex camera setup to capture images of defects, which were then labeled manually for training. Using advanced Deep Learning algorithms for image classification and segmentation, the models were built on a Python-based Keras/TensorFlow backend and trained on AWS Sagemaker, ensuring scalability.

Results and Benefits of Automated Quality Control

Darwin Edge, in collaboration within the Bonseyes consortium, delivered a working prototype that confirmed automated quality checks could be achieved at scale and in real time. Key achievements included:

• Defect Detection and Categorization: Our Deep Learning-based Computer Vision model was trained on over 5,000 images to accurately identify and categorize defects, supporting high-precision quality control.
• Scalability: The prototype was deployed in an R&D lab, showing that the model can handle large-scale, real-time quality checks.
• Improved Quality Assurance: Automated defect detection reduced the time and effort of manual inspections, especially for complex defects, lowering the chances of human error.

Partner with Darwin Edge to elevate your production line with cutting-edge quality control solutions that improve efficiency, reduce waste, and enhance product quality in real time.