Presence / Absence and Assembly Inspection
Stop missing parts, wrong assembly and cap faults on the line.
The cost of an assembly error depends on where it is found: seconds at the station, warranty cost in the field.
The inspection station compares the product against an expected component list rather than a single reference template: each component carries its own position tolerance, orientation and presence rule. Automatic positioning keeps the inspection valid even when the part is slightly shifted or rotated, and dedicated lighting removes daylight and glare. The result is a Poka-Yoke signal that physically blocks passage to the next station.
How it works
The part is aligned
The product is located and rotated automatically in frame, reducing the need for rigid fixtures.
The component list is checked
Presence, position and orientation of each component are evaluated as separate rules.
Poka-Yoke signal
On NOK the conveyor stops or the next station locks; an event record is created.
Which component is skipped, at which station and on which shift?
Assembly errors are not random: a particular component is skipped on a particular shift and usually at a particular station. Once that distribution is visible, the fix is not a warning sign but a change to work sequence or feeding layout.
| Clip / lock | 31% |
| Gasket | 26% |
| Cover | 18% |
| Label | 14% |
| Screw / nut | 11% |
Clip and gasket errors correlate with how far the feed bin sits from the operator; a layout change brings a clear drop in the first week.
| h1 | 3 |
| h2 | 2 |
| h3 | 3 |
| h4 | 4 |
| h5 | 5 |
| h6 | 7 |
| h7 | 9 |
| h8 | 10 |
The rise at the end of a shift is an attention-fatigue signal; automating the inspection stops that curve from reaching the product.
Use cases
Assembly OK / NOK
Clip, gasket and fastener inspection.
Sub-assembly line
Cable routing and component presence control.
In-pack product
Product count and presence inside the box.
Cap and lock
Cap tightness, lock and liquid-level inspection.
Technical requirements
| Camera | 1–4 cameras per station; triggered capture (encoder or sensor) |
| Lighting | Enclosed cabin or pulsed lighting; daylight effects removed |
| Decision | Under 200 ms per station; synchronous with the PLC |
| Integration | Digital OK/NOK output, conveyor stop, MES/ERP record |
| Flexibility | A new product variant is added as a recipe; no code change needed |
Frequently asked questions
How does Presence / Absence and Assembly Inspection work?
The cost of an assembly error depends on where it is found: seconds at the station, warranty cost in the field.
Are our existing cameras suitable for this solution?
Required camera specification: 1–4 cameras per station; triggered capture (encoder or sensor). Before installation we assess your camera inventory free of charge and report which points are suitable and, if needed, which camera should be added.
What results and indicators does it provide?
Key indicators: Decision time per station: <200 ms; Components checked per frame: 24; Target for missing assemblies shipped: 0. Clip and gasket errors correlate with how far the feed bin sits from the operator; a layout change brings a clear drop in the first week. Thresholds are calibrated on your own site during the pilot.
Which systems does it integrate with?
Digital OK/NOK output, conveyor stop, MES/ERP record. Events are published over REST API and MQTT, so it connects to your existing MES, ERP, VMS and alarm infrastructure.
Is it compliant with KVKK, Türkiye's data-protection law?
Footage is processed on an edge server inside your facility; raw video is not sent to the cloud. Facial recognition is not used; analytics outputs are anonymous and event clips are deleted automatically when the defined retention period ends.