manufacturing · mid-market · US Great Lakes
Metal fabricator catches defects before shipping
Escaped defects drove $240k of annual warranty claims.
Implementation cost
$96,000
Annual savings
$205,000
ROI
213% first year
Payback
5.6 months
Hours saved / yr
1,600
Timeline
4 months
Success rating
4/5
Forecast accuracy
-11%
Verified result
Predicted $230,000 a year. Actual $205,000 measured over 12 months. Warranty claims fell slower than modelled in year one.
Lessons learned
- • Budget for lighting, not just cameras
- • Retrain the model after every tooling change
Solution deployed
OpticQA Vision Inspection — Camera-based in-line inspection that catches defects before they leave the cell.
Vendor: OpticQA · 4.4/5 from 54 reviews · Within 2 business days · success rate 82%
Known limitations: Model retraining required after tooling changes; Lighting design drives accuracy
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