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How IM Gears Ensured 360° Defect-Free Bevel Gears with Jidoka’s AI-Powered Vision Inspection Infrastructure

Jidoka’s AI vision system detects critical visual defects in bevel gears, ensuring zero market
escapes, reducing costs and providing reliable inspection with 99.5% accuracy.

OVERVIEW

IM Gears, a $30 million high-precision manufacturer of automotive, hydraulics, and aerospace components, specializes in
producing critical bevel gears that demand flawless quality to ensure mechanical performance and reliability.
As production volumes increased reaching up to 10,000 units per day the company faced significant challenges with
traditional manual inspection methods.

THE OPPORTUNITY

‍Ensuring defect-free bevel gears while maintaining throughput demands a comprehensive, automated solution:

  • Full 360° inspection of gears, covering internal and external geometries.
  • High-speed inspection to meet production targets without compromising accuracy.
  • Consistent marking of accepted parts for seamless sorting.
  • Data-driven insights for shifting from defect detection to defect prevention.

JIDOKA’S APPROACH

  • Multi-Station Camera Setup
    The multi-station inspection system provides end-to-end quality control by automatically loading, flipping, and precisely checking the part’s top, bottom, inner, and outer diameters.
  • Deep Learning-Based Defect Detection
    Advanced object detection algorithms identify a wide range of visual defects, including:

    •   Face burrs, sphere damage, rust, tool marks, white phosphating marks, dents, broach issues, and more.
    •   Dimensions such as outer diameter are verified against tolerances of ±1 mm.
  • Automated Marking & Sorting
    Accepted parts are automatically marked with a green identification dot for seamless sorting,  and undergoes oiling treatment, reducing manual handling and human error.
  •  Data-Driven Quality Insights
    The system captures and analyses 30+ images per part, enabling root-cause analysis and preventive measures, rather than reactive detection.

Industry

Automotive

Deployments

Huron with Kompass

Results 1

99.5% accuracy in detecting 15+ defect classes

Results 2

10% improvement over manual inspection with automated marking and sorting

THE BIG WIN

Key achievements driving business excellence

$32KCost Savings

 

Reduces inspection labour costs and eliminates recalls

10% Improvement Over Manual Inspection

 

Enhances overall throughput and reliability.

99.5%Accuracy

 

Reliable detection of 15+ defect classes

Automated, Fatigue-Free Inspection

 

Supports end-to-end inspection without manual intervention.

Get in Touch with us about this Testimonial

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