AI-Powered Quality Control System for Manufacturing Excellence

The Challenge

A leading electronics manufacturer struggled with high defect rates and lack of visibility across PCB (printed circuit board) assembly lines. Existing quality control was manual, slow, and reactive — issues were only found after entire batches were completed, resulting in delays and scrap loss.

Our Solution

We built a real-time defect detection and analytics platform that integrates directly with smart cameras and inspection hardware. The system processes image data and operator logs to provide:

• Instant defect type classification (e.g., Missing Component, Solder Bridge)
• Shift and batch-level quality insights
• Smart filters and trend tracking dashboards
• CSV export and alerting capabilities for operators

Results & Impact

• Defect rate reduced by 32% in the first 2 weeks after deployment
• Inspection feedback time dropped from hours to under 5 minutes
• Customizable filters and reports saved operators ~40% of time per shift
• Real-time sync between factory sensors and dashboards improved responsiveness