Empowering Precision: AI-Vision in Real-Time Component Checks for Electrical Toys Manufacturing

July 25, 2024

In the bustling factories where the dreams of children take shape, a revolution is underway. The toy industry, especially the segment dedicated to electrical toys and products, is witnessing the advent of a technology poised to set a new benchmark in manufacturing excellence: AI-Vision based Real-Time Component Checks. This innovative approach is not just enhancing the efficiency of the assembly process; it is redefining the very essence of quality control.

The Technology at Work

At the heart of this transformation is the use of a 2D camera, integrated with an AI model, capable of pinpointing the coordinates of an assembly operator's hands in the video stream. This breakthrough technology goes beyond mere observation; it is an intelligent system designed to ensure that every component picked by the operator is the right one for the product being assembled.

Digitized assembly station for electric toy cars

The process begins with the operator scanning the barcode of the order sheet, which informs the system about the shop floor order currently in process. As the assembly gets underway, the AI vigilantly monitors the operator's interaction with the component boxes. These boxes are demarcated within the camera's field of view using a frontend tool that assigns specific zones to each box.

Engineering setup view for the component check

The AI's logic meticulously assesses if the hand coordinates fall within these zones, the extent of the hand's presence, and the duration of stay. This detailed analysis confirms whether the components being selected are in accordance with the bill of materials sourced from the Manufacturing Execution System (MES).

Operator live view for the component check

In the event of a mismatch, where a wrong component is inadvertently picked, the system immediately alerts the operator through real-time feedback on a touchscreen.

Operator live feedback view for the component check

This prompt intervention allows for the swift correction of the mistake, thereby significantly reducing the risk of assembly errors and propelling the industry closer to the coveted goal of Zero Defect Manufacturing.

The Critical Importance for Electrical Products

The application of AI-Vision based Real-Time Component Checks is especially crucial in the assembly process of electrical products for several reasons:

1.     Safety First

Electrical toys and products come with their own set of stringent safety standards. A small mistake in selecting components can lead to malfunctions, posing serious risks to consumers. This technology ensures that every piece assembled conforms to the highest safety standards, providing peace of mind to manufacturers and consumers alike.

2.     Complexity and Precision

Electrical products often involve the assembly of numerous small, intricate components. The precision required to assemble these parts correctly is paramount. AI-Vision technology aids operators in navigating this complexity, ensuring that the correct components are used every time.

3.     Cost Efficiency

Mistakes in the assembly of electrical products can be costly, leading to wasted materials and increased production times. By minimizing errors, AI-Vision based checks contribute to a more cost-effective manufacturing process, enhancing the overall efficiency of production lines.

4.     Regulatory Compliance

Electrical toys and products are subject to rigorous regulatory standards worldwide. Compliance with these regulations is non-negotiable. Real-time component checks help manufacturers adhere to these standards, avoiding costly recalls and maintaining brand integrity.

Conclusion: A Vision for the Future

As the electronics industry continues to innovate, the integration of AI-Vision based Real-Time Component Checks in the assembly process of electrical toys and other products represents a significant leap forward. This technology is not just about preventing errors; it's about instilling a culture of precision and excellence. It's about safeguarding the joy and wonder that electrical toys bring to children and adults alike. In the relentless pursuit of Zero Defect Manufacturing, AI-Vision stands as a beacon of innovation, guiding the industry towards a future where every product off the assembly line is a testament to the highest standards of quality and safety.

Product: Electric toy car

How we did it

Together with the INOYAD GmbH with headquarter in Augsburg and supported by Intel, we are proud to be bringing this solution to market. The solution is optimized for data-intensive workloads and is adaptable, vetted, and ready for immediate deployment.

The solution runs on Intel® Core™ i5 Processors which are state-of-the-art processors allowing for maximum flexibility and performance in Industrial Settings. Best in class Wi-Fi connectivity with Intel® Wi-Fi 6 (Gig +) ensures a responsive and reliable connection for immersive connectivity even in large factory spaces.

To create training data to pretrain a model for advanced hand-recognition even with working gloves, we use the Intel® RealSense™ Depth Camera D435f. With its advanced depth-sensing capabilities, this camera is designed to capture accurate 3D images and videos in real-time, making it ideal for our industrial use case.

With the Intel® OpenVino™ Toolkit, we optimize our AI models to run efficiently on Intel hardware, unlocking unparalleled performance and accuracy. A lot of workstations need to be equipped and OpenVino™ makes it easy to deploy our AI models at scale.


Kevin Denker

Kevin Denker


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