The Challenge
A leading electronics manufacturer in India needed to inspect 50,000+ PCBs daily across multiple production lines. Their manual inspection process suffered from an 8-12% human error rate, with 24 quality inspectors working in rotating shifts. Missed defects were causing costly product recalls exceeding $1.2M annually, damaging customer relationships and brand reputation.
Across multiple production lines requiring 24/7 inspection coverage
Fatigue, inconsistency, and micro-defects missed by human eyes
High labor costs with significant training and turnover challenges
Product recalls and warranty claims from undetected defects
Our AI Solution
We designed and deployed an end-to-end computer vision quality control system built for industrial-grade performance and reliability.
YOLOv8 Object Detection
Custom-trained YOLOv8 model on 100,000+ annotated PCB images, capable of identifying 23 distinct defect categories including solder bridges, missing components, misalignments, and trace defects -- all at production line speed.
- Trained on 100,000+ PCB images
- 23 defect categories identified
- Real-time detection at production line speed
Edge AI Deployment
Deployed on NVIDIA Jetson AGX Orin for on-premises processing with zero cloud dependency, ensuring sub-50ms inference latency. Integrated directly with industrial GigE cameras mounted above the production conveyor.
- NVIDIA Jetson AGX Orin for on-premises processing
- Industrial camera integration
- No cloud dependency for real-time inspection
Production Integration
Seamlessly integrated with existing conveyor systems and automated reject mechanisms. Piloted on a single production line, validated over 4 weeks, then rolled out across all 3 active lines with zero production downtime.
- Integrated with conveyor systems
- Automatic reject mechanism
- Pilot on 1 line, then rollout to 3 lines
Quality Dashboard
A real-time analytics dashboard providing defect trend monitoring, shift performance tracking, and automated quality reports. Management can drill down into defect types, line performance, and historical trends.
- Real-time defect analytics
- Trend monitoring & shift performance tracking
- Automated quality reports
Results & Impact
Measurable outcomes delivered within the first 6 months of deployment
vs 88-92% human accuracy
150 to 1,200 PCBs per hour
Reduced 24 to 4 inspectors
Defect rate: 2.4% to 0.3%
2 product recalls prevented
Fastest payback across all projects
Technology Stack
Industrial-grade AI systems purpose-built for production environments
Computer Vision
PyTorch, YOLOv8, OpenCV
Edge Computing
NVIDIA Jetson AGX Orin
Industrial
GigE cameras, conveyor integration
Analytics
Real-time dashboard, automated reports
"Bytesar's computer vision system has revolutionized our quality control. We're catching 99% of defects compared to 90% before, and we're doing it 8x faster. Customer complaints have dropped to nearly zero."
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Our manufacturing AI specialists can assess your production line and build a custom computer vision solution tailored to your quality control needs.
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