Artificial intelligence (AI) is renowned for its advanced image recognition and classification capabilities, making it the ideal tool for automated optical inspection (AOI). What opportunities does AI open up in AOI, and how does it enhance production efficiency?
Automation and enhanced component classification
AOI equipment suppliers are increasingly adopting AI technology to meet the growing demands of the industry, while manufacturers continuously seek ways to integrate this technology into their production processes. In surface-mount technology (SMT) production, where many processes are already highly automated, AI enables increased speed and repeatability in tasks requiring precise analysis, adaptation, and evaluation. A practical example of AI application in manufacturing is automated optical inspection, which vividly demonstrates the potential of modern AI solutions for quality control.
In AOI, AI algorithms excel due to their classification abilities, which are also successfully applied in other fields such as medical diagnostics, autonomous vehicles, and content moderation. In the context of industrial quality control, these mechanisms achieve greater effectiveness in detecting and analyzing defects. Traditional approaches required experts to configure systems and perform real-time image assessments, which was time-consuming.
Today, AI-supported commercial systems enable automatic adaptation of component libraries, accelerating the identification of part types based on images and allowing for the automatic selection of optimal settings. Furthermore, AI supports three-dimensional measurement of components, generating data for parts not found in existing libraries, which speeds up adaptation and improves the efficiency of AOI systems.
Intelligent secondary evaluation
Although AI has simplified and accelerated component library management, its potential in AOI extends beyond these basic applications. This technology is ready to deliver even greater value to manufacturers by leveraging machine learning and classification capabilities for precise defect evaluation directly on the production line. Relying on human judgment to classify defects as actual flaws, false alarms, or false negatives can be time-consuming and introduce variability into the production process.
Some defects, such as missing components, misalignments, or significant soldering issues, are relatively easy to identify. However, others may require more thorough analysis and precise determination of whether they fall within acceptable standards. When this task relies on operators, differences in experience and individual criteria can affect evaluation quality. This slows down inspection, causes some defects to be overlooked, and results in unnecessary rework due to overly strict evaluations.
Operator assessments are then fed back into the AI software, allowing the model to continuously adjust and quickly adopt best practices, reducing errors stemming from human evaluation. Once properly trained, the AI model can perform independent evaluations, enabling operators to work faster and with greater confidence while maintaining a high level of precision.
From support to full automation
The next step after implementing AI-supported secondary evaluation is the full automation of the optical inspection process, achieving the highest standards typically upheld by experts. Yamaha’s AI Judgement software enables seamless remote connectivity with repair stations and can directly share analysis results with AOI systems operating on the production line, continuously improving inspection accuracy.
Yamaha AI Judgement software for AOI systems provides operators with detailed information regarding Good/NoGood classification decisions, including images, tables, and confidence indices. In the case of soldering defects, such as solder bridges or contamination, the software displays a graphical heatmap and a calculated anomaly index. Evaluations of other defects, such as character recognition, are presented using a match ratio. This software generates a comprehensive report containing anomaly detection calculations and excessive detection suppression.
AI has the potential to significantly improve AOI processes by accelerating the creation of component libraries and automatically generating data for missing parts. Thanks to image classification capabilities, AI is ready to be implemented on production lines to support and, ultimately, automate secondary defect evaluations. In the past, this task required the attention of skilled specialists; today, AI enables operators to achieve a similar level of proficiency. The path to full automation, from assembly to optical inspection, driven by continuous learning, ensures ongoing improvements in production quality and efficiency.
RENEX Group and Yamaha – Comprehensive Support for SMT and AOI Production
RENEX Group, as an authorized distributor of Yamaha, specializes in delivering comprehensive solutions for SMT and AOI production. The offering includes Yamaha’s full range of electronics assembly equipment, including solder paste printers, 3D solder paste inspection machines, and 3D PCB inspection devices. Leveraging Yamaha’s expertise in servo control and imaging technologies, these systems ensure high precision and speed.
RENEX Group also supports customers through technical and commercial consulting, service, and training. At the RENEX Technology and Training Center, partners and customers can select the appropriate technologies and equipment with expert assistance, using available production lines and demonstration rooms. The group provides support not only for SMT production but also in areas such as vision systems, industrial robots, electrostatic discharge (ESD) protection, and cleanrooms.
RENEX also operates the largest IPC Authorized Training Center in Central and Eastern Europe, which has been providing training in IPC standards and ESD protection for over 20 years. The group offers customized training on production equipment operation and industrial robot programming. Its extensive service, awarded the title of Best SMT Service in Europe by Yamaha, demonstrates the high-quality support RENEX delivers to its customers.
