Overview

An automotive Tier 1 manufacturing client approached MJ Engineering to design and install a custom automated vision-based part inspection system. The client needed to ensure that every assembled model was correctly oriented—a task previously done manually, which was both time-consuming and prone to human error. The new system allows operators to place each part for inspection using a color touchscreen interface that displays pass/fail status in real time.

Our Solution

MJ Engineering designed a fully automated, vision-based inspection cell capable of 100% verification of specified part characteristics. The system was built to detect the presence, position, and orientation of features using a Teledyne Dalsa BOA color vision camera and optimized lighting. Passing parts are automatically marked with quick-dry ink for traceability. The portable cell was modeled in SolidWorks and programmed to handle multiple part types with customizable inspection profiles. Operators can easily select models, view inspection status, and manage production from the integrated HMI.

Outcome

By replacing manual inspection with a fully automated system, the client achieved precise, repeatable verification for every part, meeting their customer’s zero-error requirement. The system now performs over 30 individual inspections per part, with tolerance accuracy down to 1 mm. The solution not only improved inspection accuracy and throughput but also reduced operator fatigue and inspection time, providing a more reliable and efficient quality control process.