Manual and semi-auto assembly after placement is where missing, wrong, and reversed parts creep in—and they often surface only at the finished unit. This plant ran DaoAI AI-AOI for high-takt full inspection after assembly, stopping problems at the board level.
After placement, industrial control boards still go through extensive through-hole and assembly steps: connectors, headers, jumpers, heatsinks, and shielding cans are fitted by hand or semi-automatically, and omission, wrong model, reversed orientation, and not-fully-seated parts creep in easily. Such defects may not affect the board's appearance but surface only at unit assembly or field use, where rework is costly. The prior manual final check, limited by speed and attention, could only spot-check key locations and never covered everything.
The plant deployed DaoAI AI-AOI for completeness inspection of the assembled board: the model judges, at each key location, whether the component is present, the model correct, the orientation consistent, and the part fully seated. With APDT positive-sample learning, each board type is modeled on a few good boards, and semantic false-call filtering avoids treating allowable assembly tolerance as a defect. The system runs inline full inspection at high takt, upgrading a once spot-checked step to board-by-board coverage; a new board type switches over in five minutes with zero code, no line stop or reconfiguration.
Inspection coverage
- Missing parts: are connectors, headers, jumpers, heatsinks all present
- Misload: is the model / polarity / orientation correct
- Not seated: are through-hole parts fully inserted
- High-takt inline full inspection replaces manual spot-checks of key locations
Catch an assembly omission before the board leaves the line, not at the finished unit.
After go-live, combined detection of missing parts and connector misloads reached over 97%, assembly defects were caught at the board level, and related defects flowing to the unit stage fell markedly; inline full inspection replaced manual spot-checking, easing both the labor burden and the miss risk at the final-check station.