Overview
IM Gears, a $30 million high-precision manufacturer of automotive, hydraulics, and aerospace components, specializes in producing critical bevel gears that demand flawless quality to ensure mechanical performance and reliability.
As production volumes increased—reaching up to 10,000 units per day—the company faced significant challenges with traditional manual inspection methods.
Opportunity
Ensuring defect-free bevel gears while maintaining throughput demands a comprehensive, automated solution:
- Full 360° inspection of gears, covering internal and external geometries.
- High-speed inspection to meet production targets without compromising accuracy.
- Consistent marking of accepted parts for seamless sorting.
- Data-driven insights for shifting from defect detection to defect prevention.
Jidoka’s Approach
- Multi-Station Camera Setup
The multi-station inspection system provides end-to-end quality control by automatically loading, flipping, and precisely checking the part's top, bottom, inner, and outer diameters. - Deep Learning-Based Defect Detection
Advanced object detection algorithms identify a wide range of visual defects, including:- Face burrs, sphere damage, rust, tool marks, white phosphating marks, dents, broach issues, and more.
- Dimensions such as outer diameter are verified against tolerances of ±1 mm.
- Automated Marking & Sorting
Accepted parts are automatically marked with a green identification dot for seamless sorting, and undergoes oiling treatment, reducing manual handling and human error. - Data-Driven Quality Insights
The system captures and analyses 30+ images per part, enabling root-cause analysis and preventive measures, rather than reactive detection.
Big Wins
Key achievements driving business excellence
$32KCost Savings
Reduces inspection labour costs and eliminates recalls
99.5%Accuracy
Reliable detection of 15+ defect classes
10% Improvement Over Manual Inspection
Enhances overall throughput and reliability.
Automated, Fatigue-Free Inspection
Supports end-to-end inspection without manual intervention.
With Jidoka’s AI-powered vision inspection system, manufacturers can ensure defect-free bevel gears, protect brand reputation and maintain high-quality standards. The solution enables precise 360° inspection, data-driven insights and efficient sorting, setting a new benchmark for automated gear inspection in high-volume manufacturing.
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