Process Automation

Overview

Vision-Based Process Control enables industries to bring automation, accuracy, and intelligence directly into production lines by using AI vision to monitor, validate, and control each step of a process. Whether it's verifying component placement, monitoring assembly steps, detecting abnormalities, or confirming motion sequences, Flagman's AI-powered vision system ensures every operation runs exactly as it should — with zero guesswork, zero delays, and zero dependency on manual oversight. Using computer vision, deep learning analytics, and machine-connected control logic, Vision-Based Process Control transforms any visual task into a real-time, automated decision-making layer that improves productivity, quality, and safety across the plant.

The Challenge

Industrial processes break down when humans are relied upon for visual checking or supervision. Common challenges include:

Key Challenges

• Inconsistent visual inspection accuracy
• Missed defects or process deviations
• Poor visibility in fast-moving lines
• High reject rates due to unnoticed errors
• Delays caused by manual confirmations
• No traceability or evidence for QA teams
• Dependency on experienced operators

Flagman Solution

AI-driven visual control eliminates these gaps by creating a continuous, automated, repeatable monitoring layer that works reliably across shifts, lighting conditions, and production speeds. Flagman's vision engine continuously analyzes live video feeds from cameras positioned around the production point. It detects objects, movements, orientation, count, surface quality, patterns, or any visual indicator defined in the SOP. Whenever the system identifies a deviation — such as a part missing, misalignment, improper operation, abnormal machine movement, or incorrect sequence — it instantly triggers alerts through tower lamps, buzzers, or on-screen guidance. It can also signal machines through PLCs to stop, hold, or switch to a safe mode. All observations, alerts, image frames, and process results are stored in the dashboard, where supervisors can review performance, adjust settings, and export logs for audits or quality reports. This creates a continuous feedback loop that strengthens process control and reduces operational unpredictability.

Key Features

• Object & component verification detecting presence, absence, orientation, positioning, and completeness of parts
• Real-time process monitoring tracking ongoing operations and validating that every step occurs precisely as expected
• Defect & anomaly detection identifying irregularities such as deformation, color changes, contamination, or unexpected motion
• PLC/Machine integration enabling automated intervention — stopping machines, redirecting workflows, or activating alarms
• Multi-camera architecture using multiple angles to ensure full visibility of complex processes
• Configurable visual rules allowing custom detection parameters, thresholds, and pass/fail logic
• Visual evidence logging recording every detection event for traceability, audits, and quality checks
• All-environment reliability with performance in dusty, noisy, low-light, or high-speed conditions

Benefits