AI-Powered Visual Inspection – Traffic Signal Assembly
The Challenge:
A traffic signal manufacturer relied on manual visual inspection of LED arrays, circuit boards, and housing assemblies, achieving only 78% defect detection rate. Inspectors examined 200+ units daily with fatigue-related errors causing customer returns averaging 4.5% and $280K annual warranty costs.
The Solution:
Deployed Azure AI Vision models integrated with production line cameras to inspect components in real-time. Power Apps guided inspectors through AI-flagged anomalies for verification. Fabric stored all inspection images with Power BI tracking defect patterns by supplier, shift, and assembly station.
Result:
Defect detection rate improved to 96.5%, customer returns reduced from 4.5% to 0.8%, and warranty costs decreased by 73% to $76K annually. Inspection throughput increased 40%, enabling redeployment of 2 inspectors to value-added quality engineering roles.