AI-based visual inspection system: Ensuring 70% reduced cycle times and enhanced operational accessibility

Client

The client is a world leader in advanced manufacturing, providing custom-engineered equipment for oil & gas, refinery, petrochemical, and fertilizer businesses, apart from nuclear sectors. They also offer technology-driven, quick turnaround solutions for process plants.

Challenges

The client’s challenges revolved around ensuring a comprehensive system to identify and track defects in inspection processes.

Needed to enhance subjective inspection processes
Required standardization within inspection processes
Needed to get rid of inconsistencies in hardware selection, environmental conditions, and lighting
Required an advanced system with a track record of defects with the ability to identify multiple types of issues
Needed a solution with the ability to change the acceptance criteria based on the job type
Required a system for data storage and insights generation

LTIMindtree Solution

LTIMindtree implemented an AI-based solution involving technologies such as Line Laser, Realsense 435i Depth Camera, Raspberrypi 4b Microcontroller, Capacitive 4.3in DSI Display, and C++.

Developed an AI-based solution capable of recognizing multiple types of defects in welds, ensuring a comprehensive inspection process
Implemented the ability to change acceptance criteria based on the job type, providing tailored inspection standards
Designed backend services to store inspection data and generate valuable insights, aiding in continuous improvement and decision-making
Provided an end-to-end solution with advanced hardware design, model, and portal development, and backend services
Automated the process of weld defect analysis
Created a 3D profile of the weld and running models to detect defects efficiently
Applied customized mathematical models

Business Benefits

71% Reduced Cycle Time

By implementing iNXT’s AI-powered inspection system, the overall weld inspection process was reduced from 14 hours to just four hours, dramatically improving production timelines and operational efficiency.

18 Centimeter/Minute Scanning Speed

Our advanced scanning technology enabled high-speed inspections, ensuring seamless and rapid quality checks without compromising accuracy.

Operational Accessibility

iNXT’s automated solutions reduced the reliance on personnel, allowing more team members to manage inspections efficiently, boosting flexibility and scalability across global operations.

Standardization and Reliability

We implemented standardized and automated workflows, ensuring consistent, repeatable, and reliable results, reducing human error and improving overall product quality.

Enhanced Decision-making

With iNXT, manufacturers gain access to detailed reporting and real-time data insights, facilitating better decision-making, and faster defect detection and process optimization.

Traceability and Compliance

iNXT’s solutions enhanced traceability of weld quality and defect occurrences, providing a digital record to ensure compliance with safety and regulatory standards, while improving accountability.

Hi-tech Manufacturing Businesses with Better Decision-making, Helping Them Stay Ahead of Competition

At iNXT, we empower global leaders in hi-tech manufacturing to accelerate performance, optimize processes, and drive data-driven decision-making with our cutting-edge solutions. Our AI-based Visual Inspection System revolutionizes weld overlay inspections, delivering measurable business impact across critical areas.

With iNXT, you get more than just an inspection solution; you have a powerful partner in your pursuit of efficiency, quality, and growth. Our commitment to innovation helps manufacturers like you stay ahead of the competition, delivering consistent results, detailed insights, and superior operational performance, every time.

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