Camera
Captures every component at line speed
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Automotive component manufacturer
Inspection at line speed. Accuracy without compromise.
A machine vision system that reduced dependence on manual quality inspection while fitting into an eight-hour installation window.
- Capability
- Machine Vision
- Environment
- Live production line
- Integration
- PLC + API
- Install limit
- 8 hours
The production constraint
Fourteen operators. Every shift.
Manual inspection consumed significant labour, limited the speed of quality decisions, and left production data fragmented.
Operational risk
Quality performance relied on repeatable visual judgement across long shifts.
Delivery risk
The line could not be stopped for more than eight hours during installation.
62% faster inspection cycle
98.7% detection accuracy
70% lower manual workload
Live production data
The integrated solution
One decision chain, from image to action.
ICI engineered the imaging, local computation, line controls, production interface, and visualization as a single traceable system.
Engineering principle
Keep the inspection decision close to the line. Move structured evidence upward for analysis and traceability.
System architecture
A clear path from signal to insight.
Edge computer
Processes vision models near the line
PLC
Coordinates reject logic and machine states
Production API
Structures inspection and traceability data
Dashboard
Makes quality and output visible in real time
Installation strategy
Designing the changeover before touching the line.
The eight-hour shutdown limit shaped the system architecture, off-line build, interface testing, installation sequence, and fallback plan from the beginning.
Off-line build
Assembly and logic preparation away from the production asset.
Interface simulation
PLC and API handshakes tested before the installation window.
Sequenced changeover
Every task, owner, dependency, and checkpoint planned to the minute.
Controlled ramp-up
Verification and production release against agreed acceptance criteria.
The operational result
Quality data became production data.
Inspection moved from a labour-heavy checkpoint to a connected production capability—faster, measurable, and visible in real time.
The system reduced manual inspection workload by 70% while achieving 98.7% detection accuracy. It also created a live data foundation for production and quality teams to identify patterns, trace outcomes, and improve the process over time.
Camera→Edge Computer→PLC→Production API→Dashboard→
Camera→Edge Computer→PLC→Production API→Dashboard→
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