AI Slashes Plywood Defects by 85%

A leading Indian plywood manufacturer, plagued by uneven core sheet density, deployed AI to analyze real-time images. This system, boasting 85% defect detection, slashed waste, boosted customer satisfaction, and provided valuable data for continuous improvement.

Client:

The customer we’re talking about is a major player in India’s plywood, laminates, doors, PVCs, and veneers market. Dominating the organized plywood market in India, the customer commands a 25% share. With over 5000 employees and a plant spanning 6.6 acres, their facility is situated in the eastern region of India.

Problem Statement:

The company faced a persistent quality issue for several years. Over 2% of their plywood products suffered from uneven core sheet density, a critical component for strength.This uneven distribution weakened the final product and went undetected by current manual inspection methods.The sheer volume of manufactured products made it impossible for manual checkpoints to catch this issue consistently.

Results:

☑️ 85% Reduction in Faulty Products: The AI system detects plywood sheet defects with 85% accuracy, significantly improving quality control.
☑️ Minimized Production Waste: By identifying faulty core sheets before production, the solution reduces waste and conserves materials.
☑️ Real-time Defect Alerts: Visual alerts (red lights) highlight potential issues for immediate intervention, preventing further defects and delays.

AI Solution:

Facing issues with uneven core sheet density impacting product quality, a leading plywood manufacturer turned to ThirdEye, a solution provider, who implemented an AI Image Processing and Anomaly Detection system.
This system, powered by OpenCV models and computer vision techniques, revolutionized the company’s quality control process by:

● Real-time Image Capture: High-resolution cameras captured live images of plywood sheets entering production.

● AI-driven Analysis: Advanced AI algorithms analyzed these images to measure core sheet size and density precisely.

● Defect Detection and Alerts: The system identified sheets that deviated from desired specifications, triggering real-time alerts.

● Visual Notification: A simple circuit activated a red light, alerting operators to potential defects.

This AI-powered quality control system operates directly on the production floor, enabling immediate intervention.

The plywood manufacturer’s quality control process underwent a complete makeover thanks to this AI solution. It became more efficient, costs were minimized, and the end result was an unparalleled product quality.

References:

1. Artificial Intelligence in Manufacturing Industry: Product Quality Control System

Industry: Manufacturing, Plywood Production
Vendor:ThirdEye
Client: Leading Plywood Manufacturer in India