Overview & Challenge
Cracks Hiding In Plain Sight
ForgeLine stamps 2M brackets a year for two carmakers. Human inspectors sampled 5% of output — and a single escaped crack batch in 2023 cost more than this entire project. They needed 100% inspection without slowing the line.
The hard part: acceptable parts vary. Oil sheen, tiny color shifts and lighting flicker all look like defects to naive systems — false rejects would have idled the plant.
Approach & Solution
Recall First, Then Precision
For safety parts, missing a defect is far worse than flagging a good one. We tuned ForgeCheck for near-total recall, then drove false rejects down with controlled lighting, multi-angle cameras and a fast human review for borderline cases.
- 4-camera inspection cellTop, side and two angled views fused per part.
- 180ms decisionsEdge inference keeps pace with the 120ppm line.
- Per-part traceabilityEvery part's verdict and images stored for audits.
Related Service
Built with our Computer Vision practice — inspection cells and edge inference.
