Surface defects on metal sheets such as scratches, dents, cracks, and coating issues often escape manual inspection due to inspector fatigue, high line speeds, and human subjectivity. These undetected flaws inevitably lead to costly rework, high rejection rates, and damaging downstream quality claims from customers. Our vision analytics solution enables consistent, high-speed surface inspection with objective defect classification, providing a digital eye that never tires. By ensuring only quality-approved material moves forward, we empower manufacturers to stabilize their output quality and protect their brand reputation through automated precision
High-speed defect detection for scratches, dents, cracks, and coating inconsistencies
Objective classification using AI models to eliminate human error and inspection fatigue
Inline quality assurance to trigger real-time marking or rejection of defective sheets
Captures micro-level surface defects across wide metal sheets at high production speeds
Advanced Defect Classification
Automatically categorizes issues like scratches, stains, cracks, and dents for targeted analysis
Real-Time Inline Inspection
Operates seamlessly at the end-of-line or within the process to provide instant quality feedback
Automated Rejection Triggers
Integrates with physical sorting systems to mark or divert defective material automatically
Defect Trend and Pareto Analytics
Visualizes the most frequent defect types to help teams focus on root-cause elimination
Upstream Process Correlation
Maps defect occurrences back to process conditions to identify why quality is fluctuating
Visual Audit Evidence
Stores high-definition images of detected defects for verification and quality audits
QMS and MES Integration
Streams quality data directly into your Management Systems for centralized operational oversight
Why Faclon Labs
Key strengths behind accurate and scalable industrial surface inspection
Reflective Surface Expertise
Proprietary vision models specifically engineered to handle glare and metal reflectivity
Custom Defect Taxonomy
We build and tune defect categories tailored to your specific product and material grades
Rapid AI Model Tuning
Leverage our AI SDK to quickly refine detection accuracy for new product variants
No-Code Quality Dashboards
Empower quality managers to create and customize reporting views without software coding
High-Speed Edge Inference
Processes visual data locally on the line to ensure zero latency at high manufacturing speeds
Production-Grade Deployment
Secure, OT-compliant systems designed to withstand the heat and vibration of metal plants
Seamless ERP and QMS Connectivity
Bridges the gap between the production floor and enterprise-level quality management
Multi-Line Scalability
A unified architecture that easily scales from a single inspection point to plant-wide coverage
Minimal Operator Dependency
Reduces the training burden and variability associated with manual visual inspections
CASE STUDY - METAL SHEET / SURFACE DETECTION
Precision Quality Control: Automated Surface Inspection for a Metals Leader
Faclon implemented an AI-based surface inspection system at a large metals processing plant to replace subjective manual checks for high-grade metal sheets. The system monitors the production line in real-time, identifying and classifying micro-defects that were previously missed at high line speeds. This digital quality gate provides 100% inspection coverage, ensuring that only sheets meeting strict metallurgical standards are shipped to the customer
30% Reduction in Quality Rejections by identifying process deviations in real-time
Early Fault Detection prevented the shipment of defective batches, avoiding costly downstream claims
Improved Material Flow Stability by automating the sorting and marking of scrap material
Data-Driven Quality Adoption enabled the plant to correlate specific defects with upstream furnace conditions
.svg)
