Automated Quality Assurance with Industrial Machine Vision
Reliable inline inspection backed by local support across the Americas
Defective parts, incomplete assemblies, unreadable codes, dimensional deviations and surface defects can lead to scrap, rework, customer complaints and unplanned production costs. Manual inspections and sample-based checks are often insufficient for high production volumes and demanding quality requirements.
OCTUM develops and integrates industrial machine vision and automated optical inspection systems for automated quality control. Each solution is engineered around the product, relevant defect characteristics, production speed and existing machine environment.
As a machine vision system integrator, OCTUM combines cameras, optics, lighting, software, mechanics and interfaces into a complete inspection system. Products can be inspected directly during production, results documented and defective parts rejected in a controlled manner.
OCTUM USA in Charlotte, North Carolina, provides customers in the United States, Central America and South America with a local point of contact for technical coordination and support. Our teams in the US and Germany work closely together throughout the project and system lifecycle.
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OCTUM at a glance
- industrial machine vision since 1996
- more than 6,000 systems installed worldwide
- custom-engineered machine vision and AOI solutions
- in-house software expertise
- integration into new and existing production equipment
- experience in regulated manufacturing environments
- international installation and commissioning
- local support from Charlotte, North Carolina
- long-term support throughout the system lifecycle
Inspect quality directly in the production process
Inline inspection instead of downstream sample testing
Automated machine vision makes it possible to inspect products and components directly during manufacturing. Depending on the application, every product can be captured at production speed and evaluated according to defined quality criteria.
Unlike manual inspection, a correctly designed inspection system operates objectively and reproducibly. Inspection decisions are based on defined criteria and can be transferred immediately to the PLC, reject mechanism, manufacturing execution system or higher-level quality system.
A 100% inline inspection means that every product passes through the defined inspection process. Which characteristics and defects can be detected reliably depends on the inspection task, product properties, image acquisition conditions and validated inspection limits.
Automated quality inspection can help manufacturers:
- detect relevant defects early in the process
- reduce manual inspection
- evaluate every product according to consistent criteria
- reduce false rejects through stable inspection conditions
- reduce scrap, rework and the risk of customer complaints
- document inspection results in a traceable manner
- provide quality data to downstream systems
- monitor and improve manufacturing processes
- support consistent quality across multiple production sites
Typical machine vision inspection tasks
Inspect multiple quality characteristics within one system
Industrial machine vision can perform a wide range of inspection tasks. The appropriate technology depends on the product, the characteristic being inspected and the conditions within the production line.
Typical applications include:
- presence and completeness inspection
- assembly verification
- position and orientation inspection
- dimensional and geometry inspection
- surface inspection
- detection of damage and contamination
- color and product variant inspection
- text inspection using OCR and OCV
- reading and verification of barcodes and Data Matrix codes
- detection and classification of defined defect patterns
- inspection of packaging, labels and product markings
- documentation and assignment of inspection results
Depending on the system concept and required cycle time, several inspection tasks can be combined within a single inspection station or a complex multi-camera system.
The right technology for the inspection application
Cameras, lighting, optics and software as one complete system
The performance of a machine vision system is not determined by the camera alone. Reliable inspection requires a coordinated combination of lighting, optics, image acquisition, software, product handling and machine integration.
OCTUM selects technologies according to their suitability for the specific application. Depending on the inspection task, these may include:
- traditional rule-based machine vision
- 2D camera systems
- 3D machine vision
- line-scan cameras
- color and spectral imaging methods
- deep learning and artificial intelligence
- application-specific lighting and optics
- single-camera inspection stations
- complex multi-camera systems
- OCTUM’s proprietary software solutions
New technologies are not selected simply because they are currently popular. The decisive factor is whether they deliver reliable, reproducible and understandable results under actual production conditions.
From the inspection task to a production-ready system
A structured path from initial evaluation to long-term operation
Every project starts with the specific inspection application. Together with the customer, OCTUM determines which characteristics must be inspected and which technical and organizational conditions must be considered.
1. Define the inspection task and operating conditions
First, the product, relevant defect patterns, inspection characteristics and acceptance limits are considered. OCTUM also analyzes production speed, product handling, available installation space, product variants, reject handling, camera positions, machine integration, PLC communication and required data transfer.
2. Investigate technical feasibility
For demanding applications, known-good and known-defective samples are examined under defined conditions. OCTUM evaluates suitable cameras, optics, lighting and image-processing methods. The objective is to provide a realistic assessment of the technical possibilities, necessary conditions and identifiable limitations.
3. Develop the system concept
Based on the results, OCTUM develops a coordinated concept covering image acquisition, image evaluation, mechanics, software, operator interaction and interfaces. The concept considers both the required inspection performance and integration into the manufacturing process.
5. Integrate and commission the system
The inspection system is integrated into the intended production environment, configured and coordinated with the relevant machine and software systems. Depending on the project, this is followed by functional testing, acceptance testing, documentation and user training.
6. Provide long-term system support
After commissioning, OCTUM provides support for technical questions, new products and formats, changing inspection requirements, maintenance, repairs, system expansions and modernization. This allows the inspection system to remain reliable and adaptable throughout its lifecycle.
Feasibility study and proof of concept
Determine what can be inspected reliably before investing
Not every inspection application can be evaluated reliably from a description alone. Materials, surfaces, colors, reflections, defect characteristics and product positioning can significantly affect image acquisition and inspection performance.
As part of a feasibility study or proof of concept, OCTUM examines real product samples under defined conditions. Suitable image acquisition methods and evaluation technologies are identified and assessed from a technical perspective.
The study may include:
- assessment of the available product samples
- selection of suitable camera technology
- development of a lighting and optics concept
- investigation of relevant defect characteristics
- evaluation of rule-based and AI-based methods
- creation of application images
- documentation of the results
- recommendation for the subsequent system concept
- identification of technical requirements and limitations
This provides a reliable basis for deciding how the inspection project should proceed.
Integration into new production equipment
Include machine vision early in the equipment design
When developing new production equipment, machine vision should be considered as early as possible. Inspection location, product handling, lighting, available installation space, reject handling and system interfaces all have a major impact on inspection reliability.
OCTUM works directly with OEMs, machine builders, automation companies and manufacturers. Early coordination allows the inspection requirements to be incorporated into the machine design before mechanical space, controls and production sequences have been finalized.
Important questions include:
- Where can the product be inspected under stable conditions?
- How will the product be positioned and guided?
- What production speed is required?
- How will defective products be rejected?
- Which signals will be exchanged with the PLC?
- Which results must be transferred to other systems?
- How will operators interact with the inspection system?
- Which products, formats and variants must be supported?
Retrofitting existing machines and production lines
Add automated quality inspection to existing equipment
Existing production equipment can often be retrofitted with machine vision. This requires a careful assessment of the current technical conditions.
OCTUM considers factors such as:
- available installation space
- product handling and presentation
- existing lighting conditions
- production speed and cycle time
- electrical and mechanical interfaces
- communication with the machine control system
- rejection of defective products
- operator interaction and format management
- safety and documentation requirements
This provides the basis for determining which solution can be integrated effectively and which modifications to the machine or production process may be required.
Quality assurance in FDA-regulated manufacturing
Configure functions and documentation according to project requirements
In pharmaceutical and medical device manufacturing, inspection performance is often accompanied by additional requirements related to traceability, user access, data integrity and documented system changes.
Depending on the project, system configuration and customer responsibilities, OCTUM solutions can include functions and documentation designed to support requirements derived from 21 CFR Part 11, GAMP 5 and EU GMP Annex 11.
These may include:
- role-based user management
- audit trail
- recipe and format management
- controlled modification of inspection parameters
- storage and assignment of inspection results
- documented software and system versions
- interfaces to machines, MES and quality systems
- project-specific system documentation
- support for qualification and validation activities
The specific configuration is coordinated with the quality, validation and compliance requirements of the project. An inspection system alone does not automatically ensure regulatory compliance of the entire manufacturing process.
Quality inspection systems for different industries
Pharmaceuticals
Inspection of pharmaceutical containers, closures, markings, fill levels and other product-related characteristics while taking FDA-regulated manufacturing requirements into account.
>> Machine Vision for Pharmaceutical Manufacturing
Medical devices
Automated inspection of medical devices and plastic components for geometry, completeness, assembly, surface quality and product markings.
>> Machine Vision for Medical Device Manufacturing
Packaging
Inspection of labels, tubes, folding cartons and other packaging for position, print quality, codes, completeness and damage.
>> Machine Vision for Packaging Applications
Automotive
Assembly verification, code reading, dimensional inspection and surface inspection for components and assemblies in automated manufacturing processes.
>> Machine Vision for Automotive Manufacturing
Additional industrial applications
OCTUM also develops inspection solutions for metal and plastics processing, electronics, cosmetics and other industrial manufacturing sectors.
>> Explore Additional Industry Solutions
Local support across the Americas
Technical support coordinated from Charlotte, North Carolina
A machine vision system must remain stable after commissioning and throughout everyday production. Products, formats and inspection requirements change, while components age and technology platforms continue to develop.
OCTUM USA provides a local point of contact for customers in the United States, Central America and South America. The Charlotte location works closely with OCTUM’s engineering, application and support teams in Germany.
Available support services include:
- remote technical support
- planned service visits
- assistance with unexpected technical issues
- on-site service coordination
- maintenance and repairs
- spare parts consulting
- adaptation to new products and formats
- expansion of existing inspection tasks
- software and system updates
- operator and system training
- modernization and retrofit
Local coordination helps reduce travel distances, improve communication across American time zones and connect customers with the appropriate technical specialists.
Experience from customer projects
Proven cooperation with global manufacturers and equipment suppliers
OCTUM systems are used by manufacturers, OEMs and automation companies in a wide range of industries.
![[Translate to English (USA):] Unternehmenslogo der Pharmabotix AG](/fileadmin/_processed_/8/3/csm_Referenzlogo_pharmabotix_06f04a04d5.jpg "Logo Pharmabotix")
Why OCTUM?
OCTUM combines more than 30 years of industrial machine vision experience with in-house software development, technology-independent system design and comprehensive integration expertise.
Customers across the Americas benefit from:
- a local point of contact in Charlotte, North Carolina
- one partner for the complete inspection system
- technical evaluation based on the actual inspection application
- in-house application and software expertise
- experience with new equipment and existing production lines
- rule-based and AI-based evaluation methods
- experience in FDA-regulated production environments
- global engineering and project experience
- long-term support beyond commissioning
How do I know whether my inspection application is technically feasible?
For demanding applications, OCTUM examines real product samples as part of a feasibility study or proof of concept. Image acquisition, lighting, optics and evaluation methods are assessed. The results show which characteristics can be detected reliably, which conditions must be met and where technical limitations exist.
What does 100% inline inspection mean?
A 100% inline inspection means that every product passes through the defined inspection process. It differs from sample-based inspection. However, the term does not automatically mean that every theoretically possible defect will be detected under all conditions. The decisive factors are the defined inspection characteristics and the technically verified detection performance.
Can a machine vision system be retrofitted into existing equipment?
In many cases, retrofitting is possible. OCTUM analyzes the available installation space, product handling, production speed, lighting, machine control system, interfaces and reject mechanism. This provides the basis for determining which solution can be integrated effectively.
Are OCTUM systems suitable for FDA-regulated manufacturing?
OCTUM has experience with machine vision systems for regulated pharmaceutical and medical device production. Depending on the project and system configuration, functions and documentation supporting requirements derived from 21 CFR Part 11, GAMP 5 and EU GMP Annex 11 can be included.
What information does OCTUM need for an initial assessment?
Helpful information includes a description of the product, known-good and known-defective samples, the characteristics to be inspected, known defect patterns, production speed, product variants and details of the planned or existing machine environment.
Your inspection application – our technical assessment
Are you planning to automate a quality inspection, equip new production machinery with machine vision or expand an existing inspection system?
Describe your product, the relevant inspection characteristics and the conditions in your production environment. Together, we will determine which technical solution is appropriate for your application and whether a feasibility study is recommended as the next step.
The following information is particularly helpful for an initial assessment:
- product description
- images or drawings
- known-good and known-defective samples
- relevant defect characteristics
- cycle time and production speed
- product variants and formats
- information about the machine environment
- required result and data interfaces
OCTUM USA Inc.
14045 South Lakes Drive
Charlotte, NC 28273
USA
+1 (980) 431-9540
info@octum-usa.com