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CASE STUDY

Breakage Projects – Real-Time Monitoring of Production Line Breakages

We developed automated inspection systems for multiple industrial clients to detect and track part breakages in real time, reducing waste, increasing productivity, and ensuring full traceability across production lines.

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Industry

Manufacturing & Quality Control

Deployment

Real-time computer vision inspection

Scope

Multi-client implementations for industrial production lines

Core KPI

Reduced material waste and improved detection speed

Overview

In industrial manufacturing, component breakages often go unnoticed until after material losses accumulate. Manual inspection processes are slow, error-prone, and reactive, resulting in rework, higher costs, and poor visibility into the root causes of failures.

The Breakage Projects initiative was created to automate breakage detection across multiple clients, providing real-time monitoring, centralized dashboards, and full historical traceability for smarter decision-making.

The Challenge

  • Failures were detected only after losses had accumulated.

  • Dependence on human inspection led to inconsistency.

  • Lack of traceability hindered root cause analysis.

  • Additional costs due to rework and undiagnosed problems.

Our Solution

We implemented automated inspection and monitoring systems for breakage detection:

  • Cameras installed at key points on the production line.

  • Computer vision algorithms to detect and classify breakages in real time.

  • Centralized dashboard for operators and managers to monitor live status.

  • Consolidated reports by batch, operator, and production period.

Business Benefits

  • Reduced waste: immediate detection prevents material loss.
  • Higher productivity: eliminates time spent on manual inspection.
  • Quality assurance: objective, standardized defect classification.
  • Transparency: digital records for audits and certifications.

Technical Highlights

  • Continuous computer vision monitoring of parts and components.

  • AI defect detection to identify and classify breakage patterns.

  • Structured database linking each event to batch, time, and operator.

  • Web dashboard for remote, real-time visualization and reporting.

Key Results

Automated detection validated in pilot production lines.

Real-time monitoring improved incident response and reporting accuracy.

Initial POCs confirmed feasibility and scalability for factory-wide deployment.

See It in Action

  • Real-time computer vision inspection system.
  • Dashboard with alerts and historical reporting.
  • Structured database for traceability and audit.

Smarter Manufacturing with Real-Time Breakage Detection

Discover how computer vision can reduce waste, improve quality, and bring full visibility to your production line.

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