Manufacturing processes commonly involve complex tasks that are difficult for human beings to handle simultaneously and with precision. By employing artificial intelligence, automation, predictive analytics as well as Internet of Things (IoT), manufacturers can monitor all processes and equipment in real-time.

Manufacturing industry

Manufacturing industry

Manufacturing processes commonly involve complex tasks that are difficult for human beings to handle simultaneously and with precision. Furthermore, in comparison to other businesses, more parameters affect the final product quality. Artificial intelligence(AI)-assisted visual inspection (VI) solves both of these obstacles by intelligently discovering hidden patterns in manufacturing processes or roadmaps. By employing Fourth Industrial Revolution (4IR) technologies including AI, automation, predictive analytics as well as Internet of Things (IoT), manufacturers can monitor all processes and equipment in real-time. This empowers them to leverage the full value of their data to make better and faster decisions. In other words, AI is a game changer for manufacturers due to its capabilities in reducing production costs, required quality control, downtime, etc. Moreover, using AI in manufacturing can enhance efficiency and quality. The manufacturing process includes several sequential and dependent steps. It may take very long for an operator to trace the exact step where the problem resides. Whereas AI-powered control systems can give managers a real-time view of the manufacturing process and problems, by analyzing constantly sampled data. And it’s not only large companies that can make use of AI-powered VI, but we can also offer solutions for small industries. Even though a relatively high capital investment might be required to integrate intelligent machines in the manufacturing process, the return on investment (ROI) is high enough to make it extremely cost-effective because of significantly reduced operational costs. Our AI-powered system is a great opportunity for progressive organizations, in industries where various tasks from supply chain to quality control play critical roles, to go beyond their production goals.

The applications of AI-powered inspection in manufacturing

Two major tasks can be highly promoted in manufacturing using AI-powered systems: Forecasting and Detecting anomalies or outliers. Sometimes the same inputs in the same system lead to distinct outputs, which makes it difficult for operators to find the problem. AI on the other hand can easily solve issues in various manufacturing stages including supply chain, logistics, packaging, label inspection, organization, fabric inspection (mesh, tear, yarn), metal and plastic welding seam inspection, surface inspection, transportation, and much more. The following points summarize the most important applications of AI in manufacturing:

  • Predictive maintenance: AI prediction can minimize accidents, downtime, and related costs and reduce them by up to 30% by analyzing maintenance logs and past sensor data. Based on information on when and why a problem occurred and how it was resolved, our AI-powered system can precisely predict the maintenance time and whether a specific part needs replacement or repair, long before a failure occurs. So managers can proactively prevent failures and keep production going which in turn increases throughput.


Predictive maintenance

  • Quality control: A more precise quality control process will significantly reduce manufacturing costs. Using our AI-assisted 360-degree VI across plants, production lines, and warehouses, product defects can be rapidly and precisely detected with up to 90% improvement in compared to traditional methods, resulting in scrap reduction, an increase of up to 20% in production throughput, and up to 35% better product quality. If the final product suffers from low quality, our AI software triggers an alert to humans or robots to take further action.
  • Optimization of production planning and scheduling: Even for complex products, our AI-based system analyzes raw material availability, production capacity, and customer demands to offer the best production plan and schedule, and even identify and eliminate bottlenecks in the overall process. AI evaluates the performance of each step in terms of duration, cost, and operators. The resulting insights help manufacturers streamline each step and make the right decisions.
  • Supply chain: Using our AI machine, stock and demand levels will be precisely analyzed to minimize costs and wastes related to the supply chain. AI-generated reports can be used by manufacturers to predict orders and proactively prepare for them. The high price volatility of raw materials is another key challenge for manufacturers. To maintain or promote your share of the market, you need to predict prices and make the best decisions when supplying your production process. AI excels at making predictions and providing you with the right information.
  • Automating complex tasks: Manufacturing processes often involve complex steps which must be monitored by operators. Using humans to operate and monitor these processes incurs additional costs and makes mistakes more probable. AI-powered robots have the ability to monitor their actions for accuracy and performance and also incorporate their mistakes into their training to improve as they operate. Automating all complex tasks allows the production managers
  • the opportunity to quickly adjust production plans and materials flow schedules and enhance worker productivity. Automation of recurrent actions, enhancing competency, minimizing human error, improving the production model, safer work environment as well as promoting the final product quality are some of the perks of incorporating AI into manufacturing processes. Moreover, robots can operate 24/7, resulting in non-stop production and maximizing profit.


Automating complex tasks

  • Innovations: Using intelligent machines, engineers are able to quickly generate a great number of designs for a product. The AI-powered software can also optimize multiple parameters to achieve the best outcomes.
  • Tracking worker safety: AI-powered VI can automatically monitor safety violations (like workers not wearing hard hats, face shields, goggles, gloves, vests, respirators, safety shoes, coveralls, etc.) 24/7 and assigned predetermined penalties. This feature can greatly promote worker safety.