AI sound-based fault detection system in manufacturing

TMA Solutions has developed an innovative AI sound analysis system designed to enhance real-time fault detection during the valve manufacturing process. By leveraging cutting-edge AI technology, the system achieves an impressive 99% faultless product rate, significantly improving the consistency and reliability of product quality. 

This solution automates the detection and removal of faulty products, enhancing quality control and manufacturing efficiency, thereby positioning the client at the forefront of technological advancement in the manufacturing industry.

Our client is a prominent manufacturer in the construction materials industry, specializing in the production and supply of essential items such as pipe accessories, spray cans, labor helmets, and high-quality engineering plastics. Based in Vietnam, the company is committed to leveraging technological advancements to maintain exceptional quality control standards across its product lines, ensuring that every item meets rigorous quality benchmarks.

As the client's business expanded, the limitations of traditional manual quality checks became increasingly evident. With a growing volume of orders, existing quality control processes struggled to uphold the high standards expected in valve manufacturing.

• Increased inconsistencies and errors: As production scaled, inconsistencies and potential errors in product quality became more frequent, posing a risk to client satisfaction and brand reputation.
• Limited labor force: The existing workforce was unable to thoroughly inspect each product for faults before delivery, which further exacerbated quality issues.

Recognizing these challenges, the client sought a proactive solution that could detect and correct faults during the manufacturing process itself. TMA Solutions, a leading Vietnamese software outsourcing company with expertise in AI applications, was engaged to develop an advanced AI-powered fault detection solution that could automate quality checks, thereby minimizing human error and enhancing production efficiency.

TMA Solutions implemented a sound-based fault detection system that utilizes advanced AI to identify anomalies during the valve manufacturing process. Key components of this solution include:

• Sound detection: Sound sensors capture audio signals generated during the valve tightening process, providing valuable data for analysis.
• Model classification: The collected sound data is processed and input into a classification model, which distinguishes between normal and faulty valves. This classification allows for accurate identification of products that do not meet quality standards.
• Notification system: Upon detecting a fault, the system sends signals to a robotic arm responsible for removing faulty products from the production line. This ensures that only high-quality items proceed through the manufacturing process, further enhancing overall product quality.

The implementation of TMA Solutions’ AI sound analysis system has provided significant benefits, including:

• Enhanced quality control: Real-time fault detection capabilities have led to a substantial improvement in product quality consistency and reliability, achieving a faultless product rate of up to 99%. 
• Increased production efficiency: The automation of fault detection and product segregation streamlines manufacturing operations, reducing bottlenecks and downtime. This increase in efficiency allows the client to fulfill orders more rapidly and effectively, meeting the demands of a competitive market.
• Scalability: The system is designed with flexibility in mind, allowing it to adapt to increased production volumes without necessitating proportional increases in labor. This scalability is crucial for supporting the client’s ongoing growth and ensuring sustained operational effectiveness.