Context
The customer produced very small components with complex shapes, where defects were irregular and difficult to define.
Problem
Standard inspection systems from major vendors could not handle the defect variability. Other vendors proposed 3D vision, which:
- Increased system cost
- Slowed inspection speed
- Exceeded what the production line could accept
What the Customer Needed
A solution that could detect unstructured defects without increasing cost or cycle time.
Hypernology's Solution
Instead of relying on 3D vision, Hypernology:
- Selected lighting optimized for the product's surface characteristics
- Chose cameras specifically matched to the product geometry
- Applied data refinement techniques to handle irregular defect patterns
This allowed reliable inspection using 2D vision, even where 3D was assumed necessary.
Outcome
- Inspection achieved with lower cost and faster speed
- Complex, unstructured defects reliably detected
- Customer avoided unnecessary 3D system investment
Lesson
More advanced technology is not always the best solution. Simple, well-designed systems can solve complex problems without unnecessary cost.