Riverside, CA
A Riverside precision components manufacturer was operating with a 12% defect rate that triggered costly rework and customer returns. Equipment downtime was unpredictable — machines failed without warning, halting production lines for 6-18 hours at a time. Quality inspections were manual and caught defects only after they had propagated through multiple production stages.
We built an AI quality control system using computer vision cameras at key production stages to detect defects in real time — before defective parts moved further down the line. Predictive maintenance sensors monitored equipment vibration, temperature, and current draw to flag machines approaching failure. A production analytics dashboard gave plant managers visibility into throughput, defect rates, and efficiency by line, shift, and machine.
Conducted a comprehensive audit of all production stages, equipment condition, quality control checkpoints, and failure modes.
Installed computer vision cameras at 8 critical inspection points and trained the defect detection AI on 50,000+ labeled part images.
Deployed IoT sensors on 24 critical machines and built the anomaly detection model that predicted equipment failures 48-72 hours in advance.
Built the production analytics dashboard and trained plant managers and shift supervisors on using real-time data to drive operational decisions.
Real-time defect detection reduced material waste from 12% to 8.6% by catching defects before they propagated through the production line.
Reduced downtime and improved scheduling enabled the same facility to produce 45% more output per shift.
Predictive maintenance reduced unplanned downtime from 14 hours per machine per month to under 9 hours.
Combined savings from reduced waste, lower rework costs, and improved throughput generated $2.4M in annual operational savings.
“We used to find out about quality problems when customers called to complain. Now we catch them in real time on the production floor. The ROI was faster than any technology investment we've ever made.”
Let’s discuss how Calidigi can deliver results like these for your industry — with a custom strategy built around your goals.