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Automated optical inspection at Gates Albert

Case Study

0 PPM
2M+ pcs/yr

Zero-Defect Inspection

Elimination of faulty part shipments through automation and visual inspection

Achieving zero defects (0 PPM) in high-volume precision manufacturing is one of the most demanding requirements in today’s supply chain—especially for annual volumes exceeding 2 million components.

Gates Albert meets this challenge through advanced automated inspection systems and a robust quality management system, ensuring every part shipped meets exact customer specifications.

By the numbers

0 PPM
Defect rate achieved
100%
Parts vision-inspected
2M+
Parts verified per year
01

The Challenge

A customer required over two million precision components annually with a strict zero defects (0 PPM) mandate. This level of quality placed significant strain on traditional inspection methods, where manual sorting and sampling introduce risk, inconsistency, and inefficiency.

Maintaining 100% inspection coverage without slowing production or increasing costs was the core challenge.

Zero-Defect Inspection — supporting photo
02

Our Solution

To eliminate variability and ensure consistent quality, Gates Albert implemented the Retina Automated Vision Inspection System—a high-speed, inline inspection solution designed for precision parts.

The Retina system delivers:

  • 100% automated inspection of every part, eliminating reliance on sampling
  • Real-time defect detection and sorting to prevent nonconforming parts from reaching the customer
  • Inspection speeds exceeding hundreds of parts per minute, supporting high-volume production environments
  • Repeatable, operator-independent results that remove human error from the inspection process
Zero-Defect Inspection — supporting photo
03

The Results

  • Verified 0 PPM performance across high-volume production runs
  • 100% part inspection with zero reliance on manual sorting
  • Improved process consistency and traceability through real-time inspection data
  • Increased throughput without compromising quality standards
  • Reduced quality-related disruptions and customer risk

Send us your print.

Upload a drawing or describe your part — our team responds with pricing, lead time, and manufacturability feedback from engineers who know multi-spindle turning.

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