Automating Quality Control on a Shoestring, a Case Study

Dependence on manual inspections for quality control often results in errors, especially after prolonged periods of work that heighten the risk of missed defects. There is no shortage of expensive commercial inspection systems that can carry out the quality control work satisfactorily. However, small to medium-sized enterprises (SMEs) often face challenges in adopting these new systems for their production workflows because of the associated integration risks, high cost, and skill complexity. To address these issues, a portable, cost-effective, and automated quality inspection system was developed as an introductory tool for SMEs. Leveraging computer vision, 3D-printed mechanical parts, and accessible components, this system offers a 360-degree inspection of production line products, enabling SMEs to explore automation with minimal investment. It features a brief training phase using a few defect-free parts to reduce the skill barrier, thus helping SMEs to transition towards smart manufacturing. These help to address the main technology adoption barriers of cost, risk, and complexity. The system’s performance was validated through repeated testing on a large sheet metal chassis installed in uninterruptible power supplies (UPS), confirming its effectiveness as a steppingstone toward more advanced smart manufacturing solutions.