Case Study — Q4 2024
Architected an end-to-end computer vision inspection system across 3 production lines — designing the data pipeline, model serving infrastructure, and edge deployment strategy that catches 99.1% of defects at 30fps, saving €0.8M annually in scrap and rework.
Results after 90 days in production
Interactive Detection Pipeline
Click a sample to simulate inspection
The Problem
The client operated 3 high-speed production lines outputting 2,400 parts per hour. Manual visual inspection caught only 87% of defects — dropping to 79% on night shifts. Each escaped defect cost an average of €3,200 in warranty claims. But the deeper problem was architectural: there was no scalable system in place to integrate vision AI into the existing factory infrastructure.
Legacy PLCs, proprietary camera protocols, air-gapped networks, and zero MLOps maturity meant this wasn’t just a model problem — it was a full-stack systems integration challenge. The client had already failed one pilot with a vendor who delivered a high-accuracy model but no viable path to production deployment. They needed a solution architect who could design the entire pipeline end to end — from camera placement to model serving to operator dashboards — and make it work within their existing OT environment.
Architecture Decisions
Execution
Technology