Vossberg Automotive inspects thousands of components an hour. Manual spot-checks let defects slip through to costly downstream stages. Pulse watches every part, in real time, on the cameras the factory already owned.
Quality control sampled roughly one part in twenty. Defects discovered at final assembly cost up to fifty times more than at the station where they originated — and some reached customers.
The line runs at takt times that leave under 40 milliseconds per frame for a decision, on a factory floor where new hardware approval takes a year. The system had to run on existing cameras and industrial PCs.
We trained defect-detection models on the plant's own imagery, compressed them for edge inference, and deployed them to the industrial PCs already mounted on the line. Pulse flags a defect before the part leaves the station and signals the PLC to divert it.
A dashboard tracks defect classes over time, turning quality data the factory never had into process improvements upstream.
What we built
Pulse now inspects 100 % of parts at full line speed. Detection reached 99.2 % with a false-positive rate operators actually tolerate, escaped defects fell by two thirds, and the system paid for itself in seven months.
“We expected a research project. We got a production system that our line operators trust — running on hardware we already owned.”