AI Quality Control

AI quality control that never sleeps.

100% inline inspection at production speed. 99.8% defect detection accuracy, zero sampling bias and a real-time decision on every part.

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Engine bay under inspection with components boxed as OK in green and NG in red — OK 92% · NG 87%

Pass

Every unit inspected
Every decision logged

detection accuracy: 99.8%; detection accuracy
defect rate reduction: −65%; defect rate reduction
production coverage: 100%; production coverage
ROI payback: 8-12 wk; ROI payback

What is AI quality control

Every unit inspected. Every defect captured. Every decision documented.

AI quality control replaces manual inspection with computer vision that runs 24/7, never misses a defect and logs 100% of the data.

The problems with manual inspection

Manual

Inconsistent Manual inspection accuracy varies between 60% and 85%, depending on operator fatigue, training and attention.
Slow 30 to 120 seconds per unit for a manual check, against milliseconds for AI.
Expensive 2 to 4 full-time inspectors per line: €120k to €200k a year in labour.
Blind spots Sampling inspections miss 15% to 40% of defects, which then ship to customers.
No data Manual decisions are logged hours later, if at all. No visibility into root causes.

Why AI quality control works

AI vision systems do not get tired, distracted or subjective. They inspect on objective criteria: dimensional tolerances, surface defects, presence or absence of components, colour consistency and contamination. Every unit, every time.

Speed Milliseconds per unit, against 30 to 120 seconds manually.
Accuracy 99.8% detection rate, with no sampling bias.
Cost €2,800 a month automated, against €8k to €15k a month in labour.
Data 100% traceability, with root cause analysis built in.

In action

A real production line, inspected in milliseconds.

Watch AI vision inspect products at production speed and catch defects in milliseconds.

Every unit checked inline, no sampling
Decision per part, with its image logged
Runs 24/7 at line speed

How it works

Capture, analyse, decide, act, log. In milliseconds.

A simple principle: the camera captures an image, the AI analyses it, a decision is made, an action is triggered and the data is logged.

01

Capture

The product moves under the AI vision system. A high-speed camera captures 3 to 8 images per second.
02

Analyse

An AI model trained on your product specifications evaluates each image against your tolerance criteria.
03

Decide

In milliseconds the AI assigns one of three outcomes to every part.
- Pass
- Rework
- Reject
04

Act

The decision triggers the downstream action: pass to the next station, divert to the rework line or eject to the reject bin.
05

Log

Image, decision, timestamp and confidence score are captured for 100% of parts and sent to your MES/ERP.

Pass means a good part, rework means fixable, reject means scrap.

What AI vision can inspect

Six kinds of checks, one system.

Each check is trained on your parts, with your own good and defective examples.

Explained

How AI detects defects: computer vision explained.

A technical walkthrough of how AI vision systems identify surface defects, dimensional errors and anomalies.

AI quality control ROI

Positive ROI in 8 to 12 weeks.

What most manufacturers see after deployment, line by line against manual inspection.

Metric	Manual inspection	AI quality control	Annual impact
Inspection speed	30-120 s per unit	Milliseconds	+€80k to €150k throughput
Detection accuracy	70-85%	99.8%	−€100k to €250k rework
Labour cost	€120k-200k a year	€0 (automated)	−€120k to €200k savings
Data logging	Manual, gaps, delays	100% automated, real time	Better decisions
Monthly software cost	n/a	€2,800	−€33.6k a year

Total annual benefit: €300k to €600k
Payback period: 8-12 weeks
ROI: 300-600%

Assembly / kitting

PIQAPART Assembly: zero-error kit assembly, powered by computer vision.

AI computer vision guides operators step by step through kit assembly. Real-time visual feedback, no room for human error and instant operator training.

Challenge

Manual kit assembly error rate of 3% to 5%: wrong parts picked, missing components, incorrect quantities, wrong sequence. New operators need 2 to 4 weeks of training, and paper manuals and static instructions create inconsistency.

Solution

PIQAPART Assembly on the workstations. Computer vision guides every step and the operator sees live feedback on screen. The system validates each part placement, blocks the process if a component is missing or misplaced, and only releases OK when the assembly is right.

What makes it unique

Real-time visual feedback. The operator sees exactly what the AI sees, on screen.
Live validation. Components are recognised and validated as they are placed.
Zero ambiguity. No paper manuals needed. An intuitive interface removes the guessing.
Instant training. New operators are productive in hours, not weeks.
Process blocking. Missing part? Wrong sequence? The system stops until it is corrected.

Results

Assembly defect rate: 0.1%; from 3-5% · −98%
Operator training time: 2-4 h; from 2-4 weeks
Rework costs: −90%; cut by 90%
Kit accuracy: 99.9%; every kit ships right
Labour cost per unit: −25-30%; fewer errors, faster assembly

Fewer errors and faster assembly bring the labour cost per unit down, and operators work guided, confident and supported. See the AI Copilot for Assembly

Get started

From assessment to full rollout in four weeks.

No long vendor lock-in contracts. No expensive infrastructure overhaul. Start with a proof of concept on your actual parts.

Week 1
Assessment

We audit your production line, defect patterns and quality criteria, and build a detailed ROI model showing where AI inspection delivers the most value.
Weeks 2-3
POC deployment

AI vision goes onto your production line and runs real-time quality control on actual parts. You see results in your own environment immediately.
Week 4+
Full rollout

Expand to the remaining lines. Integrate with MES/ERP. Connect to predictive maintenance. Go live across the facility.

Key advantage

Works with your current equipment.

No equipment replacement. Vision cameras install above or beside your existing line, and integration runs through standard sensors and actuators. You keep your current equipment and add AI decision-making on top. The ROI happens at the software layer, not in CAPEX.

The video shows how we integrate AI inspection into existing production lines without disrupting operations.

Free feasibility test