Quality Control

Overview

Flagman's Real-Time Inspection System is designed for production environments where every second matters. Instead of relying on sampling-based inspection or manual supervision, the system performs continuous monitoring of products as they pass through the production line. It validates completeness, orientation, labeling, packaging integrity, assembly accuracy, and other process-specific criteria in real time. This ensures uninterrupted quality assurance throughout the shift—regardless of speed, load, or operator availability.

The Challenge

Production lines move quickly, making it nearly impossible for human inspectors to manually verify every item. Defects often appear sporadically, sometimes only during certain batches, shifts, or machine conditions. Traditional sampling misses many of these issues. Even small inspection delays can allow dozens of defective products to pass through unnoticed, causing downstream failures or customer complaints.

Key Challenges

• Need for 100% inspection without slowing production
• Complex, multi-stage workflows
• Frequent SKU changes
• Inadequate manual oversight during peak hours

Flagman Solution

Flagman deploys AI cameras along the production flow to validate products at every critical checkpoint. The system analyzes shape, orientation, labeling, part presence, barcodes, seals, packaging quality, and assembly correctness in real time. Any deviation instantly triggers an alert, reject command, or machine hold—ensuring defective products never move forward.

Key Features

• Continuous 24×7 inspection
• Orientation & alignment verification
• Label, marking & barcode validation
• Packaging and sealing checks
• Multi-zone inspection logic
• Real-time reject signals via PLC

Benefits