Production Monitoring & Quality Control
Manufacturing — Real-time production surveillance with AI-powered quality inspection and XR-enhanced operator interfaces.
Client Context
A manufacturing company operating multiple production lines with strict quality requirements. Manual visual inspections were inconsistent, equipment failures were causing unplanned downtime, and operators needed better tools to handle increasingly complex assembly procedures.
The Challenge
Quality Variability
Manual visual inspections missed defects that accumulated across shifts, leading to downstream quality issues and rework costs.
Unplanned Downtime
Equipment failures were detected only after they impacted production, causing cascading schedule delays and cost overruns.
Operator Complexity
Complex assembly procedures and frequent changeovers required operators to reference physical documentation, slowing throughput.
Data Silos
Production, quality, and maintenance data lived in separate systems, preventing holistic performance analysis and root cause identification.
Our Approach
- Mapped production processes, quality checkpoints, and equipment maintenance cycles
- Deployed IoT sensors on critical equipment for vibration, temperature, and throughput monitoring
- Built computer vision system for automated defect detection at key inspection points
- Developed XR operator interface with step-by-step guided procedures and contextual alerts
- Unified data platform connecting production, quality, and maintenance for cross-functional analytics
Solution
An integrated production monitoring platform combining IoT sensors, MQTT-based data streaming, computer vision quality inspection, and XR-enhanced operator guidance. A unified .NET backend collects and correlates data from all sources, feeding real-time dashboards and predictive maintenance models.
Outcomes
35%
Reduction in defect rate
40%
Less unplanned downtime
XR-guided
Operator procedures