Automated Quality Assurance with Industrial Machine Vision
Detect quality defects reliably and integrate inspection directly into production
Defective parts, incomplete assemblies, unreadable codes, dimensional deviations or surface defects can lead to complaints, rework and unplanned production costs. Manual inspections and sample-based checks are often insufficient for high production volumes and demanding quality requirements.
OCTUM develops and integrates industrial machine vision and automated optical inspection systems for automated quality control. Each inspection solution is designed around the specific product, relevant defect characteristics, cycle time and existing machine environment.
As a system integrator, OCTUM combines cameras, optics, lighting, software, mechanics and interfaces into a complete inspection system. Products can therefore be inspected directly during production, results documented and defective parts rejected in a controlled manner.
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OCTUM at a glance
- industrial machine vision since 1996
- more than 6,000 systems installed worldwide
- customized machine vision and AOI solutions
- in-house software expertise
- integration into new and existing machines
- experience in regulated production environments
- international installation and commissioning
- support throughout the entire system lifecycle
Inspect quality where it is created
Inline inspection instead of downstream sample testing
Automated machine vision makes it possible to inspect products and components directly during production. Depending on the application, every product can be captured at production speed and evaluated according to defined criteria.
Unlike manual inspection, a correctly designed inspection system operates objectively and reproducibly. Inspection decisions are based on defined criteria and can be transferred immediately to the machine control system, reject mechanism or higher-level quality systems.
A 100% inline inspection means that every product passes through the defined inspection process. Which characteristics and defects can be detected reliably depends on the inspection task, product properties, image acquisition conditions and defined inspection limits.
Automated quality assurance can help to:
- detect relevant quality defects at an early stage
- reduce manual inspections
- evaluate every product according to consistent criteria
- reduce false rejects through stable inspection conditions
- reduce rework and the risk of complaints
- document inspection results in a traceable manner
- provide quality data for downstream processes
- monitor and improve production processes systematically
Typical inspection tasks
Inspect different characteristics within one inspection system
Industrial machine vision can perform a wide range of inspection tasks. The appropriate technology depends on the product, the characteristic to be inspected and the conditions within the production line.
Typical applications include:
- presence and completeness inspection
- assembly and position inspection
- dimensional and geometry inspection
- surface inspection
- detection of damage and contamination
- color and variant inspection
- text inspection using OCR and OCV
- reading and verification of barcodes and Data Matrix codes
- position and orientation inspection
- detection and classification of defined defect patterns
- inspection of packaging, labels and markings
- documentation and assignment of inspection results
Depending on the system concept and cycle time, several inspection tasks can be combined within a single station or multi-camera system.
The right technology for the specific inspection task
Camera, lighting, optics and evaluation as one complete system
The performance of a machine vision system is not determined by the camera alone. Reliable inspection is only possible when lighting, optics, image acquisition, software, product handling and the machine environment work together as a coordinated system.
OCTUM selects technologies according to their suitability for the specific application. Depending on the inspection task, these may include:
- traditional rule-based machine vision
- 2D camera systems
- 3D machine vision
- line-scan cameras
- color and spectral imaging methods
- deep learning and artificial intelligence
- different lighting and optics concepts
- single-camera stations and complex multi-camera systems
- OCTUM’s proprietary software solutions
New technologies are not used simply because they are available. The decisive factor is whether they deliver reliable and understandable results under actual production conditions.
From the inspection task to a production-ready inspection system
Structured implementation instead of individual components
Every project starts with the specific inspection task. Together with you, OCTUM determines which characteristics must be inspected and which technical and organizational conditions must be taken into account.
1. Define the inspection task and operating conditions
First, the products, relevant defect patterns, inspection characteristics and acceptance limits are considered. OCTUM also analyzes cycle time, product handling, available installation space, product variants, reject handling, camera positions, machine integration, PLC communication and required data transfer.
2. Investigate technical feasibility
For demanding applications, real product samples are examined under defined conditions. OCTUM evaluates suitable cameras, optics, lighting and image-processing methods. The objective is to provide a realistic assessment of the technical possibilities, necessary conditions and identifiable limitations.
4. Build the inspection system
Depending on the project, OCTUM handles system design, mechanical engineering, software configuration, assembly and technical integration. Coordination with machine builders, equipment manufacturers, automation specialists and quality assurance teams continues throughout the project.
6. Provide long-term system support
After commissioning, OCTUM provides support for technical questions, new products and formats, changing inspection requirements, maintenance, repairs, expansions and modernization. This allows the inspection system to be used reliably and further developed throughout its lifecycle.
Feasibility study for demanding inspection tasks
Determine what can be inspected reliably before investing
Not every inspection task can be assessed reliably from a description alone. Materials, surfaces, colors, reflections, defect characteristics and product positioning can have a significant impact on image acquisition.
As part of a feasibility study, OCTUM examines real good and defective samples. Suitable image acquisition conditions and evaluation methods are identified and assessed from a technical perspective.
The study may include:
- assessment of the available product samples
- selection of suitable camera technology
- development of a lighting and optics concept
- investigation of relevant defect characteristics
- evaluation of rule-based and AI-based methods
- creation of application images
- documentation of the results
- recommendation for the subsequent system concept
- identification of technical requirements and limitations
This provides a reliable basis for deciding how the project should proceed.
Integration into new machines and production lines
Include machine vision early in the machine concept
For new machines, machine vision should be considered as early as possible. The inspection position, product handling, lighting, available installation space, reject mechanism and interfaces have a major influence on how reliably the inspection task can be implemented.
OCTUM works directly with machine builders, equipment manufacturers and production companies. Early coordination allows the inspection requirements to be incorporated into the machine concept before installation space, controls and production processes have been finalized.
Retrofitting existing equipment
Integrate automated quality control into existing processes
Existing machines and production lines can often be retrofitted with machine vision. This requires a careful analysis of the current technical conditions.
OCTUM considers aspects such as:
- available installation space
- product handling and presentation
- existing lighting conditions
- production speed and cycle time
- electrical and mechanical interfaces
- communication with the machine control system
- rejection of defective products
- operation and format management
- safety and documentation requirements
This provides the basis for determining which technical solution can be integrated effectively and which machine or process modifications may be required.
Quality assurance in regulated production environments
Configure functions and documentation according to project requirements
In the pharmaceutical and medical technology industries, inspection performance is often accompanied by additional requirements relating to traceability, user management, data integrity and documented system changes.
Depending on the project, system configuration and area of responsibility, OCTUM solutions can include functions and documentation designed to support requirements derived from GAMP 5, EU GMP Annex 11 and 21 CFR Part 11.
These may include:
- role-based user management
- audit trail
- recipe and format management
- controlled modification of inspection parameters
- storage and assignment of inspection results
- documented software and system versions
- interfaces to machine and quality systems
- project-specific system documentation
- support for qualification and validation
The specific configuration is coordinated with the project’s quality and compliance requirements. An inspection system alone does not automatically ensure compliance of the entire production process.
Quality assurance for different industries
Pharmaceuticals
Inspection of pharmaceutical containers, closures, markings, fill levels and other product-related characteristics while taking regulated production requirements into account.
>> Machine vision for the pharmaceutical industry
Medical technology
Automated inspection of medical devices and plastic components for geometry, completeness, assembly, surface quality and markings.
>> Machine vision for medical technology
Packaging technology
Inspection of labels, tubes, folding cartons and other packaging for position, print quality, codes, completeness and damage.
>> Machine vision for packaging technology
Automotive
Assembly inspection, code verification, dimensional inspection and surface inspection for components and assemblies in automated manufacturing processes.
>> Machine vision for automotive applications
Additional industrial applications
OCTUM also develops inspection solutions for metal and plastics processing, electronics, cosmetics and other industrial production sectors.
>> Discover additional industry solutions
Support throughout the entire lifecycle
Quality assurance does not end with commissioning
Products, formats and quality requirements change. At the same time, components age and technical platforms continue to develop.
OCTUM therefore supports inspection systems beyond commissioning. Available services include:
- remote support
- scheduled service visits
- assistance with technical faults
- maintenance and repairs
- spare parts consulting
- adaptation to new products and formats
- expansion of existing inspection tasks
- software and system updates
- training for operation and parameterization
- modernization and retrofit
This allows existing systems to remain in use over the long term and to be adapted to changing production requirements.
Experience from customer projects
Proven cooperation with machine builders and production companies
OCTUM systems are used by machine builders and production companies in a wide range of industries.
Why OCTUM?
OCTUM combines more than 30 years of industrial machine vision experience with in-house software development, technology-independent system design and comprehensive integration expertise.
Customers benefit from:
- one point of contact for the complete inspection system
- technical evaluation based on the specific inspection task
- in-house application and software expertise
- experience with new machines and existing production equipment
- rule-based and AI-based evaluation methods
- experience in regulated production environments
- international project and service experience
- long-term support beyond commissioning
How do I know whether my inspection task is technically feasible?
For demanding inspection tasks, OCTUM examines real product samples as part of a feasibility study. Image acquisition, lighting, optics and evaluation methods are assessed. The results show which characteristics can be detected reliably, which conditions must be met and where technical limitations exist.
What does 100% inline inspection mean?
A 100% inline inspection means that every product passes through the defined inspection process. It differs from sample-based inspection. However, the term does not automatically mean that every theoretically possible defect will be detected regardless of the inspection conditions. The decisive factors are the defined inspection characteristics and the technically verified detection performance.
Can a machine vision system be retrofitted into an existing machine?
In many cases, retrofitting is possible. OCTUM analyzes the available installation space, product handling, cycle time, lighting, machine control system, interfaces and reject mechanism. This provides the basis for determining which solution can be integrated effectively.
Are OCTUM systems suitable for pharmaceutical and medical technology applications?
OCTUM has experience with machine vision systems for regulated production environments. Depending on the project and system configuration, functions and documentation supporting requirements derived from GAMP 5, EU GMP Annex 11 and 21 CFR Part 11 can be included.
What information does OCTUM need for an initial assessment?
Helpful information includes a description of the product, relevant good and defective samples, the characteristics to be inspected, known defect patterns, cycle time, product variants and details of the planned or existing machine environment.
Your inspection task – our technical assessment
Would you like to automate a quality inspection, equip a new machine with machine vision or expand an existing inspection system?
Describe your product, the relevant inspection characteristics and the conditions in your production environment. Together, we will determine which technical solution is appropriate for your application and whether a feasibility study is recommended as the next step.
The following information is particularly helpful for an initial assessment:
- product description
- images or drawings
- good and defective samples
- relevant defect characteristics
- cycle time and production speed
- product variants and formats
- information about the machine environment
- required result and data interfaces
