Automated Quality Control & Inspection

Robust quality control underpins all modern manufacturing processes. It's not confined to a final inspection of completed goods or components, but embedded throughout the entire manufacturing process to support accuracy, precision and continuous improvement.

We design automated quality inspection systems that embed control at every stage of the production process. Combining vision, force, torque and sensor technologies, our solutions catch defects early, verify accuracy and provide the data needed for continuous improvement and compliance.

Our automated quality inspection solutions are custom-designed to minimise defects, reduce waste, enhance consistency and ensure compliance with the highest industry standards.

Vision systems: accuracy at speed

Vision systems confirm alignment, verify dimensions and identify defects before issues move downstream.

2D vision: fast and reliable planar inspection

2D vision systems are used for planar inspections, such as surface defects or printed codes. They are effective for high-speed applications where features are on a flat plane, lighting can be controlled, or when a cost-effective solution is required. Typical uses include

Presence or absence detection: checking that all components are present and complete
Orientation and alignment: Ensuring components are positioned correctly and aligned.
Surface defect detection: identifying scratches, discolouration or blemishes on flat or uniformly textured surfaces
Barcode/QR code reading: providing traceability and verification
2D dimensional measurement: confirming lengths, widths and diameters.

3D vision: depth and shape analysis at scale

3D vision is used when more precise dimensional checks are required, features vary in depth, or parts are presented in less controlled environments. Typical uses include:

Volumetric measurement and shape analysis: measuring height, depth and complex geometries
Component seating and flushness: verifying that parts are correctly seated or assembled to a specific depth
Deformation and warpage: detecting bends or distortions
Random inspection: guiding robots to check parts that aren’t neatly arranged, for example, in bin picking.

Force and torque feedback

Unlike visual inspection, force and torque feedback measures the physical forces in assembly. We deploy automated QC solutions that use these signals to monitor assembly quality in real time, including:

Assembly verification: Monitoring torque during screw fastening and insertion forces in press-fit operations
Fastening checks: detecting stripped threads, over-tightened screws or parts not seated correctly
Depalletisation: Identifying misaligned or stuck items during picking and handling operations.

Complementary QC technologies

While vision systems are central to most QC solutions, other technologies help detect errors, confirm accuracy and keep processes stable. Used together, they catch defects early and provide data for process improvement.

Proximity and distance sensors: simple checks to confirm absence, presence or position; counting items
Load cells and weight verification: weigh products or packs to confirm quantities or identify missing components
Non-contact gauging (laser profiling): create a profile of the part to measure dimensions (including soft or delicate) materials
AI and machine learning: identify defects, anticipate problems and adjust to product changes
Contamination and foreign object detection: use vision, X-ray, or metal detection to detect unwanted materials
Process parameter monitoring: track temperature, pressure and flow and identify deviations in real-time
Data logging and traceability: store results, images and measurements with timestamps; connect to MES or ERP for tracking and analysis.

Quality control solutions: case studies

We have partnered with a range of prominent clients, and the quality control solutions we’ve implemented highlight our expertise in addressing specific manufacturing challenges:

Bluescope Steel: inspecting pressed sheet metal before assembly to prevent downstream issues
Arnott’s: vision systems to check biscuit integrity and cream filling thickness before robotic placement

Interested in Quality control automation and inspection? Get in touch and speak with one of our specialists.

Our work with BHP

Increase in operational efficiency

10 %

Savings achieved and counting

$ m

Client retention rate

Projects successfully completed

We are industry agnostic and design quality control solutions to support a range of manufacturing disciplines.

Food and Beverage

Pharmaceutical

Building Products

Renewables

Consumer Electronics

Fast-Moving Consumer Goods (FMCG)

Mining

Intralogistics

Manufacturing

Waste and recycling

FAQs

What level of QC accuracy can I expect?

Accuracy depends on the product and process, but our systems are designed for repeatable results within tight tolerances. Utilising AI, vision and force/torque sensors, our automation solutions will consistently outperform manual inspection methods.

How does automated QC affect costs and quality?

By detecting defects early, automated QC reduces waste, rework and recalls. It also enables 100% inspection, improving product quality and consistency while lowering manual labour costs and boosting throughput.

What kind of data do your QC systems capture?

Inspection results, images, force/torque graphs and pass/fail data are logged with timestamps. Linked to MES or ERP, this enables full traceability, root cause analysis and ongoing process improvement.

How do I make contact with Applied Robotics to start scoping an automated quality control solution?

Simply complete and submit our contact form. Our solutions team will get in touch to set up a discovery call.