3 Options for Quality Control That Will Support Your Manufacturing Efficiency

Quality control is an essential part of any manufacturing process, but it can be challenging to find the best approach. AI inspection is a growing trend that offers some distinct advantages over other quality control options.

AI inspections are more accurate than visual examinations and machine vision, while also being cheaper and more flexible than these traditional methods of quality control. This article will explore how AI inspection compares with human vision and machine vision in terms of accuracy, efficiency, cost-effectiveness, flexibility, and scalability.

AI-Powered Visual Inspection

There are many different types of AI inspections, but one of the most innovative technologies is AI-powered visual inspection. This approach uses computer vision algorithms to inspect objects for defects.

AI-powered visual inspection can be used for a wide range of applications, including detecting scratches on car windshields, inspecting electronic components, and identifying flaws in food products.

This method of inspection is highly accurate. In fact, it can detect defects that are invisible to the human eye. It is also very efficient; AI-powered visual inspection can inspect large numbers of objects quickly and accurately. And because it relies on software algorithms rather than humans, AI-powered visual inspection is more reliable than traditional visual inspections.

Affordability is another important thing to consider. While many inspection solutions can be exceedingly expensive, AI inspection is highly cost effective. Moreover, it can be deployed on most off-the-shelf cameras with an internet connection, or locally with an inexpensive edge processing unit.

This type of visual inspection is scalable, too; AI inspections can be adjusted to suit different object sizes and environments. For example, AI-powered inspection is often able to account for variations in lighting and camera resolution while maintaining high accuracy. For these reasons, it is worth it to consider Simerse AI quality inspection for defect detection.

Machine Vision Inspection

Compared to AI inspection technology, machine vision systems have been around for much longer. Machine vision refers to systems that use classical image processing to detect objects with cameras or other imaging devices. Machine vision has been used for many years in industrial applications such as product identification, quality control, and automated inspection.

Machine vision solutions are excellent for highly particular applications with high degrees of automation—but they come with several disadvantages that make them less than ideal in other situations.

Unlike AI inspections, machine visions systems require an application specific camera which reduces flexibility. They also tend to be expensive, and can lack the accuracy and scalability of AI-powered visual inspections.

Return on investment is a key factor for many manufacturers. The cost of a system and its expected impact on operations are critical considerations. Machine vision systems are notoriously expensive, even for a relatively simple industrial camera.

Fortunately, AI inspection can often be deployed using an existing machine vision camera, enhancing the value proposition of both systems.

Human Visual Inspection

The most common form of quality control is human visual inspection. This involves a human inspector looking at an object and identifying any defects. Visual inspection is often used for products that are not highly automated, such as food and pharmaceuticals.

Visual inspection has many disadvantages compared to AI or machine vision inspections. It can be expensive, especially if it requires dedicated labor resources. It also suffers from high rates of error, as humans are susceptible to fatigue and bias. In addition, visual inspection is not always accurate or efficient enough for certain applications.

One key advantage of visual inspection is that it can be easily adapted to different environments and product types. Human inspectors can quickly learn how to identify flaws in new products or under different lighting conditions. Additionally, human inspectors can benefit from years of training and experience when inspecting products.

The Winner: AI-Powered Visual Inspection

AI inspection offers many advantages over its competitors, whether they are machine vision systems or human visual inspectors. Because AI is software-based, it can be updated and deployed at a moment’s notice to adapt to new manufacturing processes or product types.

Inspections powered by AI also offer unprecedented accuracy compared with traditional quality control methods. AI can be highly accurate, even in challenging light and imaging conditions. AI inspections are also flexible enough to adapt to different object sizes or environments with ease.

How to deploy AI Visual Inspection

If you would like to learn more about AI inspection solutions for your particular problem set, get in touch with Simerse. We have a team of AI experts ready to help you find the most effective AI solution for your unique needs.

We are unique in that no prior training data is required to work with Simerse. Many companies will request that you collect and label your own defect training images. At Simerse, we have collections of labeled imagery ready to go. This means that we can move faster and more cost-effectively than inferior alternatives.

Typically, manufacturers like to start with a proof-of-concept to demonstrate the value. Some companies prefer to advance directly to a full deployment so they can realize value sooner. It completely depends on your specific needs. At Simerse, we can tailor a rapid proof-of-concept to demonstrate value to senior leadership and then move to a full deployment, even across multiple facilities.

The ultimate goal of any quality inspection system is to identify defects. In our opinion, AI can give the best bang-for-the-buck and increase return on investment. AI is the future of manufacturing quality control, and Simerse AI is leading the charge.


In this article, we have compared three different types of quality control: human visual inspection, machine vision inspection, and AI-powered visual inspection. We have looked at the pros and cons of each type of inspection and determined that AI offers many advantages over its competitors.

If you would like to deploy AI-powered visual inspection in your manufacturing facility, Simerse AI is here to help. Don’t hesitate: contact us today so we can discuss how AI visual inspection will benefit you!