Low-Cost Mini AOI: Replacing Manual Visual Inspection in Electronics Manufacturing

Kitron is dedicated to delivering high-quality electronics manufacturing services (EMS) while continuously improving processes through innovation. Across our global sites, we work to develop solutions that enhance efficiency, ensure quality, and support our customers’ evolving manufacturing needs.

The Kitron China electronics manufacturing professionals recognised the challenges of manual visual inspection and developed a low-cost Mini Automated Optical Inspection (AOI) system to replace manual inspection across various production scenarios.

Challenges with Manual Visual Inspection

In the EMS industry, Through Hole Technology (THT) processes involve various scenarios that require appearance inspection, dimensional measurement, and presence/absence checks, all traditionally carried out by human operators.

This introduces several challenges, including human errors, operator fatigue leading to missed defects and errors, high labour costs, and dependency on manual work. Additionally, there is an inability to store, analyse, and trace inspection data for quality audits and a risk of inconsistent inspection quality, especially in high-mix, low-volume environments.

These challenges can affect both product quality and production efficiency, particularly when customers require traceable inspection data.

To address the challenges, the Kitron China specialists have developed and enhanced a Mini AOI system based on a standard camera platform. This system offers similar functionality to traditional AOI systems but at a fraction of the cost, making it practical and scalable for a wide range of THT inspection needs.

How It Works

The Mini AOI system combines open camera programming software and open I/O ports for flexible integration. It also includes photography and recognition functions for diverse inspection needs, input ports for triggers, and output ports for sorting control.

It automatically inspects for missing, reversed, or misaligned components, scratches, contamination, surface defects, dimensional abnormalities, and visual inconsistencies.

The Mini AOI outputs clear OK/NG judgments by capturing images and using programmed recognition. Integrated with PLCs, single-chip microcomputers, solenoid valves, relays, and jigs, it can use upstream signals to trigger inspections and automatically sort products based on results, replacing manual inspection and separation.

Low Cost, Significant Improvement

In addition to making product appearance judgments, the Mini AOI can also be integrated into robots to function as human eyes, enabling positioning, grabbing, compensation, transmission, differentiation, and judgment, becoming an indispensable part of the future automation trend.

With the knowledge and experience of a skilled engineering team, the low-cost Mini AOI offers reliable, consistent appearance inspection and enables traceable data storage for customer audits. It reduces the manual inspection workload while seamlessly integrating into existing production lines and is compatible with robotic systems for positioning, picking, and sorting.

The Kitron China specialists are already planning to integrate Mini AOI in other manual processes to improve efficiency further, highlighting its adaptability and long-term potential in production.

The Mini AOI improves inspection accuracy and becomes a vital part of the automation process, supporting quality improvement while reducing dependency on manual operations.

Summary

By replacing manual inspection with automated, traceable, and reliable checks, we help ensure consistent product quality, faster production, and reduced risk of errors.

At Kitron, we are committed to applying the latest technologies to deliver the highest possible quality and efficiency in electronics manufacturing. The Mini AOI system is an example of a practical, innovative solution that improves processes while reducing costs for customers.

As competition in Asia grows stronger, Kitron China continues to strengthen its position by focusing on cost-efficient automation solutions. These efforts ensure that our customers benefit from consistent quality, reliable delivery, and competitive costs in the dynamic market.