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ClearQuality

Vision AI for Smart, Efficient Manufacturing

Automate and augment manufacturing operations with Vision AI. Vision AI captures and analyzes image data from the production floor to increase automation, drive continuous improvement, and empower better decision-making.

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Why Vision AI for Manufacturing?

Compared to manual inspection, Vision AI detects issues faster and more reliably, while continuously capturing data that supports quality improvement, process optimization, and safer, more productive operations.

Vision AI for Quality Control

Understanding the stack

From lens to dashboard, one partner.

Physical AI

Engineered and procured with ClearObject

  • Lighting & Optics

    Lighting and lens selection engineered for a consistent, repeatable image

  • Cameras & Positioning

    Industrial cameras, mounting and enclosures designed to your line geometry

  • Hardware Procurement

    We spec it, you own it. No proprietary ClearObject hardware

  • Edge Compute

    Ruggedized GPU appliance sized to run at full line speed

Software Intelligence

Built and managed by ClearObject

  • Inference Engine

    ClearVision models detect defects in real time at the edge

  • Line Integration

    Verdicts to your PLC and reject gate over OPC UA

  • ClearVision Hub

    Dashboards, cross-line insight and audit-ready quality records

  • Operationalization

    Value comes from Physical AI and software intelligence working together.

  • Top-to-bottom support

    We support every layer, from hardware to software, to keep your model running.

  • Mutual success

    Our agreements are structured around shared outcomes and a model that returns.

Performance envelope

Every unit inspected, at line speed.

Inference time
< 100 ms
Throughput
10–20 fps
Reject signal
< 30 ms
Edge to Hub
< 500 ms
Units inspected
100%
To Line 1 go-live
5 months

Typical envelopes, not fixed specifications. Maximum bounds are agreed at implementation onset and validated on your own imagery before production.

Inspection modules

Eight modules, one edge platform

Every module publishes into the same PLC signal set and ClearVision Hub, and modules can be combined on a single line.

  1. 01

    Defect Detection

    Segmentation and classification on every frame: where the defect sits, how large it is and what kind it is. Scratches, dents, cracks, voids, seal and fill faults, surface contamination.

  2. 02

    Code Date & Label

    Confirms every printed code and label is present, readable and where it belongs before product leaves the line, with an optional OCR read.

  3. 03

    Operator Quality Control

    Your best operators’ accept and reject calls become training labels, so criteria that resist written rules are applied to every unit, every shift.

  4. 04

    Dimensional Analysis

    In-line length, width, diameter, gap, position, fill height and count from a calibrated camera, checked against tolerance bands you configure.

  5. 05

    Anomaly & Foreign Material

    Trained on good product only. Foreign objects, debris, unseen defect types and process drift are flagged with no library of defect examples.

  6. 06

    SOP & Human Behavior

    Verifies people follow the procedure: the right steps, in the right order, with the right PPE. Step compliance per cycle, with an event clip and alert.

  7. 07

    Sensor Fusion: Vision + LiDAR

    For harder use cases. Vision’s semantics plus LiDAR’s geometry catch volume, shape, depth and low-contrast faults either sensor alone would miss.

  8. 08

    Custom Complex Module

    Multi-stage pipelines for problems beyond a single model: multi-camera fusion, sequenced checks, assembly completeness and kit verification.

Process monitoring

Catch a clogged nozzle before it costs a batch

Spray nozzles that apply glue or binder drift and clog, and the first sign is usually bad product. ClearVision measures the angle of every spray fan as it runs and alerts the line when a nozzle falls out of range.

  • Measures both edges of every nozzle’s spray fan, continuously
  • Flags a narrowing or lopsided spray as soon as it drifts out of tolerance
  • Alerts operators at the line, so the nozzle is cleaned before a batch is ruined
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Vision AI Use Cases for Manufacturing

Vision AI from ClearObject turns video streams into actionable data to make manufacturing more efficient, safer, and more profitable.

  1. Quality Control

    Real-time quality control across continuous or batch production with Vision AI - If you can see it, we can see it better, faster, and more consistently.

  2. Operations Efficiency

    Vision and sensor data help AI understand material waste, work interruptions, downtime, and more to help predict and improve workflows.

  3. Vision AI checking worker PPE on the factory floor

    Worker Safety

    Enhance worker safety by ensuring proper PPE, alerting workers in danger zones, and monitoring dangerous equipment.

  4. Vision AI verifying an assembled product

    Assembly Verification

    Track small batch assembly operations to ensure products are complete and accurate according to specifications.

  • Waste Reduction

    Catch errors early and identify the root cause to increase efficiency and reduce waste.

  • Inventory Tracking

    Automate inventory visibility using Vision AI to track materials, parts, and finished goods in real time.

How we get there

A repeatable path from first use case to scaled deployment.

  • Value-focused discovery · 1–2

    Opportunity assessment

  • Frictionless data integration · 3–4

    Integration analysis

  • Rapid solution delivery · 5–7

    Minimum viable product

  • Scalable managed solution · 8–10

    Cloud deploy for product

Outcome

Scalable managed vision system

  1. 1Identify opportunities
  2. 2Define business use case
  3. 3Install hardware
  4. 4Data pipeline and features
  5. 5Build the vision model
  6. 6Evaluate
  7. 7Product onboarding
  8. 8Plan and scale deployment
  9. 9Operationalize model to PLC
  10. 10Monitor

Three-phase timeline

Five months to Line 1 go-live

Capture happens on-site in the first phase, and ClearObject does the annotation and training: no data science team is needed on your side. Lines 2 and beyond compress by roughly 70%, because models, network topology, PLC templates and OPC UA maps carry directly across.

  • Design & procurement (2 months): line survey, footage capture, hardware BOM, model training and an accuracy assessment on your own defects
  • Installation (1 month): cameras, lighting and edge provisioning, with the PLC in monitoring-only mode
  • Training & calibration (2 months): tuning on live variation, threshold recommendations and operator training; the closed loop activates on your written sign-off

Case Study

Knauf Improves Quality and Safety

ClearObject provided Knauf with a highly available and reliable Vision AI system with real-time deep learning prediction capabilities, allowing users to monitor and be alerted if manufacturing lines deviate from standards.

Since launching, Knauf has seen immediate and dramatic impacts for both the bottom line and towards reaching their ESG (environmental, social and governance) goals. Knauf is realizing millions in savings.

Read the Full Case Study
ROI in year one for Knauf Insulation
511%

Vision AI for Manufacturing Benefits

  1. 01

    Quality

    Vision AI deployed at the edge provides real-time analysis to identify defects and eliminate false-positives, improving both quality and efficiency.

  2. 02

    Efficiency

    ClearVision reduces downtime and increases throughput with insights into operations. Lines run faster, longer, and with higher accuracy than those monitored by human eyes.

  3. 03

    Profits

    Reduce waste, cut labor costs, increase throughput, and minimize downtime so QA professionals can focus on solving quality concerns, not on monitoring the lines.

  4. 04

    Safety

    ClearVision Inference Engine will identify PPE violations, monitor hazardous work areas, and reduce emergency shutdowns to increase worker safety and keep operations running.

  5. 05

    Connected

    ClearVision integrates seamlessly into your existing systems, and can often use images from existing cameras.

Artifacts

Take ClearQuality with you

  1. 01

    ClearQuality product specification (PDF)

    The full stack, all eight inspection modules, platform capabilities, PLC output signals, the performance envelope and the three-phase timeline.

  2. 02

    Vision AI for Quality Control

    Why automated inspection catches what manual checks miss.

  3. 03

    Knauf case study

    511% ROI in year one with ClearVision at the edge.

Can’t Wait? Contact Us Today

The ClearObject Team of AI Experts is here to help you get started.

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