Computer Vision Quality Control System for Solar Manufacturing
Challenge
The manufacturer struggled with inconsistent quality control due to inspector fatigue during repetitive manual inspections. Additional challenges included the need for sub-millimeter measurement precision, limited labeled data for traditional machine learning approaches, poor image quality with blur and noise, and complex production environments with varying lighting and background elements.
The manufacturer struggled with inconsistent quality control due to inspector fatigue during repetitive manual inspections. Additional challenges included the need for sub-millimeter measurement precision, limited labeled data for traditional machine learning approaches, poor image quality with blur and noise, and complex production environments with varying lighting and background elements.
Solution
Techstack engineered a comprehensive computer vision system that:
- Implemented adaptive positioning algorithms to locate panels regardless of position
- Applied advanced image processing with adaptive thresholding to isolate panel components
- Created high-precision measurement using Hough Line Transform for accurate edge detection
- Designed a custom computer vision pipeline to overcome limited training data
- Built an automated defect detection and real-time alerting system
- Developed companion software for data visualization and statistical analysis
Techstack engineered a comprehensive computer vision system that:
- Implemented adaptive positioning algorithms to locate panels regardless of position
- Applied advanced image processing with adaptive thresholding to isolate panel components
- Created high-precision measurement using Hough Line Transform for accurate edge detection
- Designed a custom computer vision pipeline to overcome limited training data
- Built an automated defect detection and real-time alerting system
- Developed companion software for data visualization and statistical analysis
Results
- Achieved sub-millimeter measurement accuracy
- Dramatically reduced defective panels reaching end of production
- Significantly increased production line speed and throughput
- Minimized waste material and rejected panels
- Enabled immediate response to production issues
- Provided data-driven insights for continuous manufacturing improvement
- Achieved sub-millimeter measurement accuracy
- Dramatically reduced defective panels reaching end of production
- Significantly increased production line speed and throughput
- Minimized waste material and rejected panels
- Enabled immediate response to production issues
- Provided data-driven insights for continuous manufacturing improvement