- Conference Article
- 10.1115/imece2025-166607
Deep Learning-Powered Machine Vision for Quality Assurance in Manufacturing
- Nov 16, 2025
- Kyle O’hern + 2 more +2
Abstract This paper presents the development of a machine vision (MV) system powered by deep learning (DL) to automate quality assurance in high-mix, low-volume manufacturing. In such environments, where multiple part numbers with varied configurations are produced within a single cell, the risk of shipping assemblies with missing or incorrect components is high. MV systems, which are non-contact and integrate easily into existing workflows, offer an ideal solution. However, their success depends heavily on optimized imaging conditions, careful camera selection, and model tuning. To address this, extensive experiments were conducted to determine the ideal imaging setup, including camera type, lighting arrangement, and background configuration, ensuring consistent, high-quality image capture suitable for training robust DL models. The captured images were used to evaluate and fine-tune multiple DL architectures, such as ResNet, EfficientNet, and GoogLeNet, using transfer learning techniques. These models were trained to identify component mismatches and verify assembly accuracy against the bill of materials (BOM). The best-performing models achieved over 96% classification accuracy across 25 product types, enabling detection of defects before packaging. Designed for seamless integration into existing assembly lines, the system supports real-time inspection and feedback, facilitating immediate corrective action. Future work includes deploying the system directly onto production lines, optimizing, and extending it to other product categories. This research demonstrates the effectiveness of AI-driven inspection in improving quality control, minimizing human error, and supporting scalable, efficient manufacturing operations.
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