97% Labor Reduction: Vision Solution
Machine vision eliminated 24 hours/week of manual counting. Small investment, massive ROI, zero rejected lots since implementation.
The Challenge: A Critical QC Bottleneck
Norman Noble manufactures miniature precision parts for medical devices. Their quality control process was consuming massive resources:
The Manual Process
- Three separate operators independently counted miniature parts
- If counts mismatched, all three had to count again
- 24 labor hours per week consumed by this single task
- A single miscount risked the entire lot being rejected
This was an unsustainable use of skilled labor for a repetitive task—and the risk of lot rejection made automation essential.
The Solution: Vision System with Poka-Yoke
Machine Vision Counting
High-resolution camera and industrial lighting system automatically counts parts in trays with 100% accuracy. Instant results vs. hours of manual counting.
Poka-Yoke Error-Proofing
System prevents operator from skipping a tray or counting the same tray twice. Foolproof process ensures no human error.
Visionary delivered a complete custom machine vision system in 4 months. The system automatically:
- • Captures high-resolution images of parts in trays
- • Uses machine learning algorithms to identify and count parts
- • Logs all counts with timestamp and operator ID
- • Prevents double-counting or skipped trays through smart sequencing
- • Generates reports for quality assurance documentation
Vision System Photos
The Result
Since implementation: No lots have been rejected due to inaccurate counts.
Additional Benefits
- Instant results: Counts completed in seconds vs. hours
- Data traceability: Every count logged with timestamp
- Redeploy skilled labor: Three operators freed for value-added work
- Zero lot risk: Eliminated possibility of entire lot rejection
- Scalable: Can add more systems for other part types
Have a Quality Control or Inspection Challenge?
Machine vision eliminates human error and provides 100% inspection at production speeds. Small investment, massive ROI.
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