AI Defect Detection for Zero Escapes & Built-in Quality in Manufacturing

Defect detection

Detect Defects at Source with Jidoka’s AI Defect Detection Solution

With Jidoka's AI-powered vision inspection, you can detect product defects with 99% accuracy and remove manual inspection bottlenecks.

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Trusted by industry-leaders for zero-defect production

THE PROBLEM

Manual quality control is hurting your reputation and bottom line

High Defect Escape Rates

Lead to customer complaints and costly product recalls

High Defect Escape Rates

Lead to customer complaints and costly product recalls

High Defect Escape Rates

Lead to customer complaints and costly product recalls

High Defect Escape Rates

Lead to customer complaints and costly product recalls

THE PROBLEM

Why Manual Inspection Fails Modern Manufacturing

Relying only on human inspectors in high-speed production lines leads to errors, delays, and costly escapes.

High Defect Escape Rates

Manual checks miss hidden flaws, leading to customer complaints, warranty claims, and expensive product recalls

Inspector fatigue

Human error increases with long shifts and compromises inspection quality, leading to production bottlenecks.

Lack of defect data

Without digital data traceability, manufacturers cannot run root cause analysis or improve processes.

Erratic production

Unreliable inspection causes delays, inefficiencies, and inconsistent product quality — directly impacting profitability.

The Solution

Eliminate defects and reduce COPQ with AI-powered optical inspection

Our Cognitive Product Inspection system, Kompass™, paired with modular vision hardware, delivers end-to-end automated inspection to improve and validate quality standards.

Learn more about Kompass

Catch every defect, from every angle

Deploy AI-powered 360° inspection for comprehensive defect detection
Customize AI models for industry-specific parts & defects
Scale with modular vision hardware for complex parts or for flat components

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>99.5%

defect detection accuracy vs. 90% with manual inspection

15-30%

savings on recalls and
downstream process costs.

Inspect at full production speed

Process ~12,000 FMCG parts/100 automotive parts per minute
Automate repetitive inspections to free skilled operators for high-value tasks
Integrate with standard production lines; no workflow disruptions.

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<12-18

month ROI for FMCG  and Automotive

33%

improvement in  throughput

Maintain consistent standards 24x7 across shifts and operators

Standardize inspection algorithms as per Quality Assurance requirements to remove inspection bias
Trigger automatic rejections through integrated hardware systems
Capture and digitize operator expertise with AI training modules

>$30K

annual savings on quality control staffing

Up to 40%

reduction in false  rejections

Drive process improvements with end-to-end traceability

Record digital twins with complete image history for every shipped part
Generate batch-wise defect analytics with visual libraries for root cause analysis
Connect shop floor data through Edge AI for real-time process insights and optimization

15%

reduction in defective products with proactive kaizen driven by AI Insights and Analytics

10-15%

decrease in rework and  scrap costs driving sustainablity

Frequently Asked Questions

Can AI visual inspection be integrated into existing quality control setups?

Absolutely. Most modern AI-powered systems are designed to retrofit existing cameras and inspection hardware, augmenting, not replacing, legacy setups. This makes deployment faster, less disruptive, and more cost-effective.

How accurate are AI-powered visual inspection systems compared to manual inspection?

AI systems typically outperform human inspectors in today’s day & age. However, in the case of Jidoka’s Kompass, we deliver over 99% defect detection accuracy while handling high throughput consistently and without fatigue. This reduces false negatives, inspection bottlenecks, and human error.

How does AI defect detection compare to traditional machine vision systems?

AI-powered systems use deep learning to identify complex anomalies, like scratches, deformations, or subtle misalignments, that rule-based machine vision often misses. They adapt, learn, and evolve with your production environment.

How quickly can an AI defect detection system be implemented, and what’s the ROI timeline?

Many systems can be deployed in as little as 2–4 weeks using no-code or plug-and-play platforms. ROI is typically realized within 6–18 months, thanks to reduced rejects, fewer recalls, and higher inspection throughput.

Is AI visual inspection accessible for small-to-medium manufacturers, or only for large enterprises?

That’s a myth. AI inspection solutions are scalable and cost-effective for businesses of all sizes. Deployment can begin with critical production areas and expand gradually to maximize budget efficiency and impact.

Can AI visual inspection systems support remote or hazardous environments?

Absolutely. Remote visual inspection (RVI) allows operators or AI systems to analyze inspection data from a safe distance, ideal for environments that are unsafe or inaccessible to humans.

customer success

See AI Defect Detection in Action

Global leaders trust Jidoka’s AI defect detection solutions to replace error-prone manual checks and achieve faster throughput, zero defect escapes, and measurable ROI across diverse industries.