Camera-based quality control system

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About the project

The client needed a reliable way to ensure that only parts meeting the required quality standards could leave the production process.

The solution was a fully interlocked Quality Gate designed to eliminate operator override and prevent non-conforming parts from being released.

Sinergy’s Role
  • Sinergy managed the project end to end, bringing together two specialist partners in China: one responsible for the hardware and the other for the software.

    Our role included defining the technical interfaces between the two systems, managing communication throughout the project, coordinating design reviews and integration, and supporting commissioning at the client’s facility through final handover.
The Solution
  • Each part is locked into the inspection station, photographed, and automatically compared against an approved reference.
  • If the part passes inspection, the system permanently marks it as approved and releases the machine.
    If the part fails, it remains locked in place and an alert is sent to the Quality Department. Only authorized quality personnel can reset the system and remove the rejected part.
  • The solution was designed to be modular and scalable.
    The number of cameras, optics and inspection criteria can be adapted to different part geometries and tolerances, allowing the client to expand the system as production requirements evolve.
Key Challenges
  • Flexible System Configuration – Designing an adaptable inspection system that could be quickly adjusted for different products and batches by a non-specialized operator.
  • Meeting a Tight Budget – Achieving the required performance within the client’s budget by sourcing key components separately and using a local integrator, significantly reducing supplier procurement overhead.
  • Scaling the Solution – Expanding the initial concept to larger inspection stations and a greater number of units, requiring broader sourcing and coordination across multiple suppliers.
  • Western Software Integration – Integrating Western inspection software into an existing Chinese-built system to meet the end customer’s security and IP requirements, using a specialized third-party partner in East Asia.
Results

Contractual Risk Protection

We negotiated payment terms under which 40% of the machine cost was payable only after the client approved its performance at the facility in Israel.

Collaborative Development

The client’s engineers worked directly with the manufacturer throughout development, with remote trials and continuous refinement of the concept.

End-to-End Support

Sinergy managed the process from commercial negotiations and technical coordination through production quality control and shipment.

Significant Cost Saving

A comparable solution from a leading local integrator had been quoted at more than twice the cost.

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