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.
The approach
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
Results 2
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.