10 Common Problems in Production
And how to ensure production quality with AI
In today’s production landscape, companies are under constant pressure to reduce costs, increase efficiency, and meet the highest quality standards. However, in real life errors, manual processes, and fluctuating material quality often pose challenges that not only cost time but also have a significant impact on financial resources.
Using AI in production processes can mitigate many of these problems or avoid them altogether. ivii iriis, our AI-based visual inspection system, is the perfect solution for this. It allows users to detect errors early, minimize material waste, and ensure consistent quality – all in real-time.
In this blog post, we will highlight the 10 most common problems in production – and how ivii iriis can help to solve them while reducing costs, improving customer satisfaction and increasing quality at the same time.
1. Production scrap and material loss: How to reduce scarp and costs
Scrap is a significant problem in production, as defective parts are often detected only at the end of the production process. This leads to valuable resources being wasted and increases production costs. Besides the material waste, corrective actions are required to replace the defective parts, which also imply additional financial expenses. This problem particularly affects industries with high production volumes, where even small errors can impact a large number of products. By detecting and correcting such errors early in the process, ivii iriis helps to minimize production scrap, therefore reducing material costs while also optimizing production times.
2. Fluctuating product quality: How to ensure consistent production quality
Inconsistent product quality is a common issue in manufacturing that can negatively impact both production performance and customer satisfaction. Fluctuations in quality, increase the number of products that need to be reworked and even the number of customers who submit complaints. In some cases, they can slow down the entire production chain, as additional quality checks are necessary. With ivii iriis supporting your production process, you can make sure you get consistent results. The system monitors every step in real-time and intervenes immediately when it detects any deviations in quality.
3. Production slowdowns due to inefficiency: How to speed up the production line
In many production facilities, manual inspections and checks create bottlenecks, as there is not enough skilled personnel to carry out the tasks, slowing down the entire manufacturing process. Checking errors frequently . not only takes time but also leads to additional production downtimes. These delays directly affect the overall performance of the production line and increase the costs per produced part. With ivii iriis, the manual checking process is automated, allowing checks to be carried out continuously and without interruption.
Relevant facts
38% of surveyed companies in the DACH region are confronted with employee exhaustion (see the study/link below). To combat this issue, 52% of respondents are planning to invest in optimizing processes requiring specific skills. With ivii iriis, employees are guided and corrected as needed, so they can go home after work and be assured that they made no mistakes, regardless of education or skill level. As a result, quality increases and employee stress decreases.
4. Avoiding costly production downtime: How to prevent expensive production stops
Production downtime can prove very expensive for companies. It not only leads to direct losses in revenue but also incurs high costs for corrective maintenance and repairs. Additionally, downtime can disrupt the entire production schedule and cause delivery delays. Downtimes are particularly critical if their cause cannot be immediately identified, leading to prolonged production line stoppages.
5. Costly rework and corrections: How to reduce unnecessary reworking
If defective products are only detected after the production process has been completed, expensive rework may be required. In many cases, production lines must be stopped and employees must receive further training to fix the defects. This leads to delays, additional costs, and ultimately less profits. Furthermore, such rework disrupts the production schedule and causes delivery delays. ivii iriis ensures that there are no errors during product manufacturing, minimizing the need for rework.
6. Defective products and recalls: How to avoid costly product recalls
Products that are launched with defects are a significant risk to companies. If the defects are not detected in time, they can lead to costly product recalls, resulting in additional costs and loss of trust in the brand. The consequences of a recall are particularly serious if safety issues are involved, and can also lead to legal problems. ivii iriis helps to identify such issues at an early stage by checking every assembly and product in real-time and correcting errors immediately.
Since we introduced AI in our production, visual spot checks are no longer necessary. Every assembly is thoroughly checked for quality and documented. Complaints are now a thing of the past. Our employees can be assured that they deliver error-free work, and our customers can trust in our consistently high quality.
7. Lack of transparency and traceability: How to achieve full transparency in your production
In many production facilities, error sources and quality issues cannot be identified quickly and efficiently due to a lack of transparency. Without comprehensive documentation, it is nearly impossible to trace where a problem occurred in the production line. This often leads to delays in problem-solving and, in the worst case, production downtime. ivii iriis makes it possible to visually document every production step, allowing problems to be detected and resolved immediately.
8. Complaints and customer issues: How to prevent complaints through better checks
Customer complaints can be not only costly but also significantly damage the trust in your brand. If customers repeatedly receive defective products, this can harm your reputation in the long run and weaken your company’s market position. ivii iriis ensures that defective products do not leave the production line by bringing AI into your production to detect errors and make corrections in real-time. This way, you can minimize the number of complaints while increasing customer satisfaction.
9. High manual effort in quality checks: How to save time and money with automation
Manual quality checks are both time-consuming and prone to human error. Employees cannot always detect all the details and errors that can occur during production. Besides, manual checks require significant labor resources, which further increase production costs. ivii iriis automates this process, ensuring fast and precise quality checks and drastically reducing the manual effort.
10. Non-compliance with legal requirements and standards: How to easily meet compliance requirements
Compliance with legal regulations is essential, especially in regulated industries such as the food and packaging industries. Incorrect labeling or non-compliance can lead to severe legal consequences and costly fines. ivii iriis checks every product label and documents the entire production process, helping to ensure that your products always meet legal requirements.
CONCLUSION
Modern production is complex and prone to errors despite careful planning. To remain competitive, companies rely on AI to prevent errors in their production processes. ivii iriis offers a solution that is not only able to detect errors early in the process but also optimizes production processes and saves costs. Automated checks and continuous quality monitoring ensure that production problems no longer happen, allowing you to focus on what matters most: High-quality products and satisfied customers.
