Explore real-world implementations of Overview.ai vision systems across industries. Download detailed case studies to see how we solve complex inspection challenges.
One recipe aligns a light controller, checks four screw holes and finds loose screws on the housing. In a lab demonstration with staged defects, OV Spark Pro judged all three test parts correctly.
Alignment, color classification and AI segmentation check each coffee pod in one recipe. A 200-inspection demo run used a dent model trained on three labeled images; production reject accuracy has not yet been validated.
AI segmentation identifies rust on a bearing’s inner and outer rings across 12 inspection regions. Two labeled images trained the first model during an initial setup session; production accuracy has not yet been validated.
Alignment and AI segmentation locate tablets and mark chips and surface cracks. Six labeled images trained the first model in under ten minutes during a setup study; production accuracy has not yet been validated.
A quality engineer with no prior vision experience built MEC’s end-of-line hinge inspection on an OV Spark Pro. One recipe aligns the part and checks the washer, pin and ear, with AI Trigger starting each inspection. The camera is running in production and has moved between two lines.
Three tablet types, five AI tools, one camera. In a feasibility test using six labeled training images, OV Spark Pro returned all 15 per-type counts correctly across five captures and rejected all four captures containing defects. Validation on the customer’s own tablets is the next step.
A clear liquid coating on clear film, invisible to operators and to RGB cameras alike. A FLIR A70 radiometric thermal camera paired with the OVX grades both edges and eight middle zones on every frame, catching coating streaks worth about $20K each. First real defect caught three days after going live, with a payback period under eight weeks.
One OV20i image covers the full weld ring and separates porosity, weld displacement, and a doubled bead at pixel level, then grades the part against pixel-count rules with no external lighting. Every weld defect in the trial was identified on a single recipe, 60 minutes from setup to first detection.
The OV20i grades every weld good or NG on a single image with a confidence score, no dimensioning and no rules. Trained on three bad samples in under two minutes, the classifier caught a burn-through that slips past three layers of manual inspection and reached 100% accuracy on the first test set.
OCR verification of production dates, best-before dates, and product codes on a multi-SKU coffee packaging line for a global packaging OEM. An OV80i with dark-field ring lighting read every SKU with no training images, configured by parameter tuning in 45 minutes across roughly 8 package sizes and shapes.
Open versus closed flap detection on a personal care carton line running at 200 parts per minute with zero tolerance for missed defects. An OV20i triggered off the existing line sensor, and a classification model trained on-site in a single day reached 100% inspection coverage validated at full 200 ppm throughput.
Non-destructive seal grading on paper-based packaging at line speed. The OV20i inspects the cross seal and long seal of every package, catching the visual defects that predict bond failure: open seals, fish mouths, channels, misalignment, fold-overs, burns, and contaminants. Trained on good and bad examples supplemented with GenAI-created defects, deployed in days.
Final visual inspection on black rubber at line speed. The OV20i caught 99.6% of lab-confirmed defects versus 84% for the plant's best inspector, missed 6.4X fewer defects than the leading machine vision system, and has logged zero defect escapes since deployment. Trained on the plant's own defect language, with a live on-camera HMI and Pareto for scrap reduction.
Continuous full-web inspection on a converting line at full line speed, replacing manual sampling at the rewinder. The OV20i catches missed, over, double, and skewed perforations plus tears, stains, wrinkles, and emboss defects, trained from good product only with zero escapes as the deployment standard.
Foreign-object inspection trained on synthetic defects, validated on real metal, plastic, and a nail dropped on the belt. 15 minutes from clean reference to deployed model.
Eight defect classes (scratch, dent, tool mark, oxidation, corrosion, chip, stain, porosity) authored on a single clean connector reference image in one studio session. ~10 seconds per class, pixel-level masks attached, no real housings damaged.
One synthetic scratch authored on real wood, then retargeted across laminate, veneer, and composite finishes with Style Transfer. New finishes onboard ~12.4× faster with zero planks intentionally damaged.
One labeled wrinkle authored on a real leather seat, then retargeted across 14 OEM-spec fabric and color variants via Style Transfer. New trim specs onboard ~12.4× faster with no real seats damaged.
Multi-class defect detection on high-density automotive connectors, identifying missing, broken, and bent pins plus tiny debris with 100% accuracy and sub-second cycle times
AI-powered real-time fat content measurement and grading for beef processing, enabling consistent quality control and automated sorting in meat production facilities
Automated crack and fracture detection in pasta manufacturing, ensuring product integrity and reducing waste in high-speed production lines
AI-powered inspection system for detecting internal bore defects and dimensional variations in precision-machined components
On-site quality inspection solution providing real-time defect detection capabilities anywhere in your facility
AI-powered microscale scratch and surface defect detection on surgical instruments and medical device components ensuring 100% quality compliance
AI-powered bent pin detection on electrical connectors ensuring 100% assembly quality and preventing costly failures in high-reliability applications
Automated quality control for coffee packaging, detecting seal defects and package integrity issues in high-speed production
Real-time laser weld inspection for battery manufacturing, ensuring critical electrical connections in EV battery packs
How a leading automotive manufacturer achieved 99.8% foreign object detection accuracy on PCB assemblies
Ensuring 100% assembly accuracy for high-reliability connector systems in consumer electronics
AI-powered inspection of solder joints and component placement defects on printed circuit board assemblies
Detecting micro-dents and defects in critical high-voltage wire braiding applications
Ensuring weld quality and dimensional accuracy in critical pipe connections
Real-time verification of robotic loading operations for zero-defect assembly
Detecting braiding defects and ensuring consistent coverage in cable manufacturing
Ensuring weld quality in high-volume consumer electronics manufacturing
Comprehensive defect detection for electric vehicle control board manufacturing
High-speed inspection for tablet integrity in pharmaceutical production lines
Automated detection of yarn defects and inconsistencies in textile manufacturing
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