Wednesday, September 24, 2025

Automated Inspection - Introduction and Bibliography


Industrial Engineering - Role of Engineering, Mechanization and Automation


In process improvement study or projects, to do a task in the most productive manner, the most efficient manual method (best manual method), best mechanized method and best automation method are to be compared and the most productive method has to be employed. This comparison has to be done at element or suboperation level.

Source: Book: Motion and Time Study: Design and Measurement of Work, Ralph M. Barnes, 7th Edition, Chapter 18. Motion Study, Mechanization, and Automation.

Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System

Jidoka, a pillar of Toyota Production Systems advocates automation with human touch in all operations of a process to increase productivity of operators as well as that of total systems.


Automation of Operations in Flow Process Chart









Automated inspection uses machine vision, sensors, computer algorithms, and AI to automatically examine products, detect defects, and ensure quality in manufacturing. This process relies on cameras and software to analyze images and data for issues like misalignments, surface flaws, and deviations from specifications, offering greater speed, precision, and objectivity than manual inspection. Automated inspection lines integrate these technologies into production to maintain consistent quality, improve efficiency, and reduce costs across industries like automotive, electronics, and pharmaceuticals. 

How Automated Inspection Works
Data Capture: Specialized cameras and sensors capture images or other data from the product or component.
Image/Data Analysis: Sophisticated software, often incorporating machine vision and AI, analyzes this data to identify defects or non-conformities.
Comparison & Evaluation: The system compares the captured data against a "golden standard" or established parameters to flag any differences or deviations.
Actionable Output: The system can then categorize the defect, send the faulty item for rework, and provide insights for improving the manufacturing process. 


Key Components
Cameras and Sensors:
High-resolution cameras, 2D/3D imaging, and specialized sensors (like infrared) to capture detailed data. 
Machine Vision Software:
Software that processes images to identify defects, measure dimensions, and analyze surface properties. 
Artificial Intelligence (AI) and Machine Learning:
Algorithms that improve detection accuracy and identify a wider range of complex defects and anomalies. 
Robotic Arms:
Used to position components or move items through the inspection line, integrating the inspection with the production process. 
Benefits of Automated Inspection
Increased Accuracy & Consistency:
Reduces human error and provides more consistent quality control. 
Enhanced Speed & Efficiency:
Processes parts at speeds exceeding human capabilities, increasing production throughput. 
Cost Reduction:
Minimizes waste, recalls, and the need for large manual inspection teams. 
Improved Product Quality:
Ensures adherence to strict standards, reducing risks and improving customer satisfaction. 
Actionable Insights:
Provides data that helps identify root causes of defects and supports predictive maintenance. 
Common Applications
Printed Circuit Board (PCB) Manufacturing:
Detecting missing or misplaced components, soldering defects, and shorts. 
Pharmaceuticals:
Identifying particulate matter, cosmetic flaws, and ensuring proper fill levels. 
Automotive & Electronics:
Inspecting for surface defects, dimensional accuracy, and assembly integrity. 



Automated Inspection - Bibliography

2025

Unit 2 Automated Inspection System
https://egyankosh.ac.in/bitstream/123456789/27088/1/Unit-2.pdf



Parenteral Drug Association
Manual to Automated Inspection
https://www.pda.org/docs/default-source/pda-europe-education-presentations/2025/02_how-to-handle-test-sets/1.6-requirements-related-to-automated-visual-inspection.pdf?sfvrsn=8ffc9523_1

Evident Scientific
Evident designs and delivers automated inspection systems that meet the most challenging needs. Our systems utilize phased array and eddy current array.
https://ims.evidentscientific.com/en/automated-inspection

Automated inspection - Hexagon

Hexagon's solutions for capturing rich shop-floor data with automated inspection allows for quality assurance and process control.
 https://hexagon.com/solutions/automated-inspection  

Maximo® AI-Powered Inspection - Automated Visual Inspection
IBM
Boost Uptime with 24/7 Monitoring & Improve Quality All with IBM Maximo Visual Inspection. Unleash the Power of No-Code Computer Vision for Inspection Automation with IBM Maximo.
https://www.ibm.com/products/maximo/asset-inspection

Creating an Automated Inspection Line: A Comprehensive Guide
Published on: Nov 18, 2024
https://intelgic.com/creating-an-automated-inspection-line
 

MESH Automation

Our team at MESH Automation specializes in the design, construction, and programming of a broad spectrum of quality assurance solutions, including 2D and 3D vision inspection systems, non-contact laser measurement systems, tactile measurement tools, and advanced systems for mass flow or leak detection. We engineer these systems to be highly flexible, automatically adjusting to accommodate different products and fluctuating environmental conditions, effectively tackling your most challenging quality issues.

At MESH Automation, we deliver expert solutions in measurement, quality control, and marking/tracking. Whether integrating lasers, scribers, or print markers, we do so with unmatched professionalism. Moreover, marking is often followed by the need for precise tracking, an area where we excel, thanks to our comprehensive machinery and software capabilities.


Syntegon Technology 

Visual inspection machines
From manual inspection to intelligent automation – find the ideal visual inspection solution for you.

Visual inspection is a critical requirement for parenterals, mandated by regulatory authorities all over the world to ensure the highest product quality and patient safety. Syntegon is the strategic partner for both CDMOs or fully integrated pharmaceutical companies who want to achieve the most efficient inspection results.

Whether you require manual, semi-automated or fully automated visual inspection equipment, or integrated solutions with CCIT or Artificial Intelligence, Syntegon is your point of contact. With decades of experience and our Japanese heritage with a focus on quality, we are constantly developing innovative solutions to make your inspection processes ever more effective.



2024


What Is Automated Visual Inspection And How Is It Used?
Averroes
May 21, 2024

Automated visual inspection leverages technology to scrutinize products or equipment without human intervention, marking a significant evolution in quality control methodologies. 

Automated visual inspection is a technology-driven method that uses cameras, sensors, and algorithms to detect defects and ensure compliance with standards, highlighting its ability to operate faster and more accurately than human inspectors.

Applications in Industries

Semiconductor Manufacturing

Main Tools & Systems Used For Semiconductor Metrology (2024)
Averroes
May 20, 2024

Food Processing

Biopharma Manufacturing

Syntegon’s AIM Automated Inspection Machines offer the best quality inspection services powered by artificial intelligence. They  developed the  first Automatic Inspection Machine, the AIM275, in Japan in 1975. It  marked the first use of SD technology in particle detection, which has since become a staple of many pharmaceutical production facilities. Today, both camera-based inspection and SD technology can be integrated.

AIM 2|5 Series – Automated Inspection with Artificial Intelligence.

AIM 3000 ‒ Combining Visual Inspection, HVLD and Operational Excellence
Syntegon’s AIM 3000 guarantees high detection rates of moving particles by checking twice on two identical stations.

AIM 8000 Series ‒ AI-Ready, Versatile Platform for a Wide Variety of Products
The AIM 8000 is a flexible modular machine designed for customised solutions, with a vision system built to handle highly complex inspection requirements for particulate and cosmetic defects.


AIM 5022S: Automated inspection machine for syringes

Automated inspection machine for cartridges
Proven and reliable technology based on long-term experiences with dental and insulin cartridges



Automotive Manufacturing

A large, multinational automobile manufacturer responsible for producing millions of vehicles annually, engaged with IBM® to streamline their manufacturing processes with seamless, automated inspections driven by real-time data and artificial intelligence (AI).

As an automobile manufacturer, our client has an inherent duty to provide high-quality products. Ideally, they need to discover and fix any defects well before the automobile reaches the consumer. These defects are often expensive, difficult to identify and present a myriad of significant risks to customer satisfaction.

IBM worked with the client’s technical experts to deploy IBM Inspection Suite solutions to help them reduce defects and downtime while enabling quick action and issue resolution. The solutions deployed include fixed-mounted inspections (IBM Maximo® Visual Inspection Mobile) and handheld inspections (IBM Inspector Portable). Hands-free wearable inspections (IBM Inspector Wearable) were also made available for situations that required a head-mounted display.

Automated Inspection Solutions for Railroads


Mining

Medical Device Manufacturing
Construction
Solar Farms
Oil and Gas





April 10, 2024

TEST AND INSPECTION ASSEMBLY
Beyond the Human Eye: AI Improves Inspection in Manufacturing
By Ramūnas Berkmanas

Since implementing AI, a car seat manufacturer has seen a 30 percent reduction in defect rates.
Manual quality control methods limit the efficiency and effectiveness of modern manufacturing processes.
For one, manual inspection is too inconsistent. Due to factors like fatigue, human inspectors are prone to variability in their defect detection rates, which can range between 60 and 90 percent. Additionally, manual inspection is also slow. Manual processes often cannot keep up with fast-moving assembly lines, resulting in bottlenecks.

Common Use Cases are given in the article.



2021

Machine vision Based Inspection Productivity Improvement on Bottling Line - IE Case Study.


2020

AI Adds Continuous Improvement to Vision Systems
Cogniac helps manufacturers take vision system investments to the next level with AI-based models.
Peter Fretty
DEC 17, 2020


NEXIV VMZ-S3020 CNC video measuring system
December 11, 2020
Nikon Metrology

Automated Gauging for Process Control of Machining Operations

November 10, 2020


Gauging system provides 30% increase in manufacturing capacity
15 SEPTEMBER 2020
Manual gauging processes have created a bottleneck and preventing the achievement of  throughput necessary to achieve a part-manufacturing target at Olympus NDT. By automating inspection processes using a programmable shopfloor gauging system, the company eliminated the bottleneck and increased the output per hour with improved part quality and reduced scrap.


A New Programming Approach for Robot-based Flexible Inspection systems
William Brice Tekouo Moutchiho
utzverlag GmbH, 27-Mar-2019 - 226 pages
Preview

CNC Lathe In-Process Gauge

Supplier: Autonetics

The guage is a single part: the gauging head. The head was adapted for the FANUC robot tending the machine/cell. The robot grips the gauge as needed in a quick, automated tool change.  

Inspection Process
After the first roughing pass, the robot brings the measurement head into the machining envelop and positions it at the end of the part. A scan is then started and the robot move across the length of the part. Based on the scan, a 2D point cloud of the part is constructed. The point cloud is quickly processed and various diametrical and axial features are analyzed. The results are displayed on the Autonetics HMI. The measurements are automatically sent to the machine tool allowing the final cutting pass to remove the exact amount of material. After the last cutting pass is made the part is scanned by the robot with the gauge once more for a final assessment of the part.

Advancements in Automated Inspection - EWI - 2017
https://www.slideshare.net/EWI_engineering/advancements-in-automated-inspection

Flexible Measurement Systems - Robotic Inspection
https://www.dynalog-us.com/automated-in-line-gauging.htm

https://www.dynalog-us.com/case-study-world-first-calibrated-fms.htm
https://www.dynalog-us.com/case-study-katayama-automates-in-line-measurement.htm

https://www.amtcpl.com/software-based-automatic-multi-gauging-systems.html

https://blog.eaglegroupmanufacturers.com/precision-machined-parts-measuring-tools-every-cnc-shop-should-have

Gauging System Intelligent Process Control Software Automatically Updates CNC Tool Offsets
15 Feb 2018


Automatic Measurement in CNC Machines

Sipotek Machine Vision Systems

In Process Part Measurement - HaaS Tips - Video
https://www.haascnc.com/video/tipoftheday/ffzi6rwicuu.html

6 Factors to Consider Before Moving to Automated Inspection
A properly programmed automatic-visual-inspection system can significantly reduce the risk of bad inspections, and lead to reduced costs over time.
Dr. Helmut Hamfeld
JUL 05, 2016
https://www.machinedesign.com/markets/manufacturing-equipment/article/21832077/6-factors-to-consider-before-moving-to-automated-inspection

https://www.automation.com/en-us/articles/2009-2/automated-inspection-gaging-systems-improve-qualit

4 ways - Machine vision cameras or laser sensors integrated into equipment
2. Separate inspection station with Machine vision cameras or laser sensors
3. Turnkey systems with Machine vision cameras or laser sensors designed for specific component or family of components.
4. Robots to handle parts or cameras
https://blog.jrecorp.com/blog/four-types-of-automated-inspection-systems




Springer Handbook of Automation

Shimon Y. Nof
Springer Science & Business Media, 16-Jul-2009 - Technology & Engineering - 1812 pages

Automation is undergoing a major transformation in scope and dimension and plays an increasingly important role in the global economy and in our daily lives. Engineers combine automated devices with mathematical and organizational tools to create complex systems for a rapidly expanding range of applications and human activities. The Springer Handbook of Automation incorporates these new developments and presents a widespread and well-structured conglomeration of new emerging application areas of automation. Besides manufacturing as a primary application of automation, the handbook contains new application areas such as medical systems and health, transportation, security and maintenance, service, construction and retail as well as production or logistics. This Springer Handbook is not only an ideal resource for automation experts but also for people new to this expanding field such as engineers, computer scientists, designers. It is edited by an internationally renowned and experienced expert.

Automating Quality Systems
J.E. Tannock


1988 - Report FMS - Automated Inspection

Four key conclusions can be made based on the information available about automated inspection in flexible machining systems.
1. There are very few FMS installations that have automated inspection fully integrated into the system. 
2. A major factor is the reluctance of management to invest large amounts of capital because of concerns about the length of the payback period.
3. Many vendors, user groups, and research institutions are actively involved in research and development in all aspects of automated inspection.
4. The trend in FMS automated inspection is toward controlling the process through in-process gaging and deterministic metrology.


Updated  24.9.2024, 29.9.2022,  23 Sep 2021, 17 December 2020
First published 16 July 2020
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