100% inline inspection: why sampling is no longer enough

For years, sampling-based quality control was the industry standard. But in a market that tolerates no errors, checking only part of production is a hard risk to justify. Machine vision now makes it possible to inspect 100% of units inline, without stopping production.

The limits of sampling-based control

Sampling assumes that if a sample is good, the whole batch is good. But defects are not always evenly distributed: a one-off machine fault can affect specific units that are never checked. The result is defective products reaching the customer.

What 100% inline inspection means

It means every unit passing down the line is analysed automatically before moving on. No part escapes control, and defective ones are ejected on the spot, without stopping production.

How machine vision makes it possible

Today’s systems inspect at very high speed, capturing and analysing images in milliseconds. This makes it possible to cover 100% of production even on fast lines, something impossible with manual inspection.

The benefits of total inspection

Beyond zero defects reaching the shelf, 100% inspection delivers full traceability and a continuous stream of data to spot trends, anticipate machine faults and optimise the process.

A real case

With the AIS REV 360 COMPACT system, canned-food manufacturers inspect all of their containers in 360º with Deep Learning, ensuring every product leaves flawless toward the point of sale.

  Make the leap from sampling to total inspection. Talk to AIS and find out how to apply it to your line.