AI technology could spot defective products in manufacturing

The Japanese company has trained an AI model to detect abnormalities in manufactured goods such as frayed threads and scratches.

As part of the manufacturing process, often have to be closely inspected for abnormalities, defects or production errors.

However, new AI developed by Japanese company Fujitsu could significantly reduce the number of working hours needed for this process.

Fujitsu Laboratories, a research centre under the umbrella of the ICT multinational company Fujitsu, has developed an AI for image inspection that enables highly precise detection of a wide variety of external abnormalities on manufactured goods.

The leverages an AI model trained on images of products with simulated abnormalities, without having to prepare training data that uses actual images of defective products pulled from the inspection process of a production line.

The challenge with training AI to conduct quality control tasks is that they are often trained using weighted and summed indices for individual characteristics. This can make it difficult to create a model that fully grasps all the characteristics it needs to inspect.

Fujitsu has developed a method to train an AI model so that a normal image without a variety of anomalies such as shape, size, and colour can be restored by artificially adding the simulated abnormalities to a normal image prepared for training.

According to Fujitsu, the technology achieved more than 98pc in an AUROC score, an evaluation metric used to check classification model performance.

The score was achieved in a class of products that have variations in their normal appearance, such as carpets with different fur patterns and colours on an individual basis and printed circuit boards with different wiring shapes on different parts.

Fujitsu also verified the technology’s effectiveness in a real-world setting, at the Nagano Plant of Fujitsu Interconnect Technologies, a manufacturer of electronic equipment.

According to Fujitsu, the AI succeeded in reducing the number of hours required for inspecting printed circuit boards by 25pc.

The manufacturing sector has become a major focus for digitalisation in recent years. Last week, an €11m European project was announced, which aims to use machine learning to enhance operations within the industry.

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