The deployment of machine learning (ML)-based process monitoring systems has significantly advanced additive manufacturing (AM) by enabling real-time defect detection, quality assessment, and process optimization. However, redundancy is a critical yet often overlooked challenge in the deployment and operation of ML-based AM process monitoring systems. Excessive redundancy leads to increased equipment costs, compromised model performance, and high computational requirements, posing barriers to industrial adoption. However, existing research lacks a unified definition of redundancy and a systematic framework for its evaluation and mitigation. This paper defines redundancy in ML-based AM process monitoring and categorizes it into sample-level, feature-level, and model-level redundancy. A comprehensive multi-level redundancy mitigation (MLRM) framework is proposed, incorporating advanced methods such as data registration, downscaling, cross-modality knowledge transfer, and model pruning to systematically reduce redundancy while improving model performance. The framework is validated through an ML-based in-situ defect detection case study for directed energy deposition (DED), demonstrating a 91% reduction in latency, a 47% decrease in error rate, and a 99.4% reduction in storage requirements. Additionally, the proposed approach lowers sensor costs and energy consumption, enabling a lightweight, cost-effective, and scalable monitoring system. By defining redundancy and introducing a structured mitigation framework, this study establishes redundancy analysis and mitigation as a key enabler of efficient ML-based process monitoring in production environments.
Wood defect detection is critical for ensuring quality control in the wood processing industry. However, current industrial applications face two major challenges: traditional methods are costly, subjective, and labor-intensive, while mainstream deep learning models often struggle to balance detection accuracy and computational efficiency for edge deployment. To address these issues, this study proposes CFIS-YOLO, a lightweight object detection model optimized for edge devices. The model introduces an enhanced C2f structure, a dynamic feature recombination module, and a novel loss function that incorporates auxiliary bounding boxes and angular constraints. These innovations improve multi-scale feature fusion and small object localization while significantly reducing computational overhead. Evaluated on a public wood defect dataset, CFIS-YOLO achieves a mean Average Precision ([email omitted]) of 77.5\%, outperforming the baseline YOLOv10s by 4 percentage points. On SOPHON BM1684X edge devices, CFIS-YOLO delivers 135 FPS, reduces power consumption to 17.3\% of the original implementation, and incurs only a 0.5 percentage point drop in mAP. These results demonstrate that CFIS-YOLO is a practical and effective solution for real-world wood defect detection in resource-constrained environments.
Anomaly Detection (AD) involves identifying deviations from normal data distributions and is critical in fields such as medical diagnostics and industrial defect detection. Traditional AD methods typically require the availability of normal training samples; however, this assumption is not always feasible, as collecting such data can be impractical. Additionally, these methods often struggle to generalize across different domains. Recent advancements, such as AnomalyCLIP and AdaCLIP, utilize the zero-shot generalization capabilities of CLIP but still face a performance gap between image-level and pixel-level anomaly detection. To address this gap, we propose a novel approach that conditions the prompts of the text encoder based on image context extracted from the vision encoder. Also, to capture fine-grained variations more effectively, we have modified the CLIP vision encoder and altered the extraction of dense features. These changes ensure that the features retain richer spatial and structural information for both normal and anomalous prompts. Our method achieves state-of-the-art performance, improving performance by 2% to 29% across different metrics on 14 datasets. This demonstrates its effectiveness in both image-level and pixel-level anomaly detection.
Steel wire ropes (SWRs) are critical load-bearing components in industrial applications, yet their structural integrity is often compromised by local flaws (LFs). Magnetic Flux Leakage (MFL) is a widely used non-destructive testing method that detects defects by measuring perturbations in magnetic fields. Traditional MFL detection methods suffer from critical limitations: one-dimensional approaches fail to capture spatial relationships across sensor channels, while multi-dimensional image-based techniques introduce interpolation artifacts and computational inefficiencies. This paper proposes a novel detection framework based on signal matrices, directly processing raw multi-channel MFL signals using a specialized Convolutional Neural Network for signal matrix as input (SM-CNN). The architecture incorporates stripe pooling to preserve channel-wise features and symmetric padding to improve boundary defect detection. Our model achieves state-of-the-art performance with 98.74% accuracy and 97.85% recall. Additionally, it demonstrates exceptional computational efficiency, processing at 87.72 frames per second (FPS) with a low inference latency of 2.6ms and preprocessing time of 8.8ms. With only 1.48 million parameters, this lightweight design supports real-time processing, establishing a new benchmark for SWR inspection in industrial settings.
Small Unmanned Aerial Vehicle (UAV) based visual inspections are a more efficient alternative to manual methods for examining civil structural defects, offering safe access to hazardous areas and significant cost savings by reducing labor requirements. However, traditional frame-based cameras, widely used in UAV-based inspections, often struggle to capture defects under low or dynamic lighting conditions. In contrast, Dynamic Vision Sensors (DVS), or event-based cameras, excel in such scenarios by minimizing motion blur, enhancing power efficiency, and maintaining high-quality imaging across diverse lighting conditions without saturation or information loss. Despite these advantages, existing research lacks studies exploring the feasibility of using DVS for detecting civil structural defects.Moreover, there is no dedicated event-based dataset tailored for this purpose. Addressing this gap, this study introduces the first event-based civil infrastructure defect detection dataset, capturing defective surfaces as a spatio-temporal event stream using DVS.In addition to event-based data, the dataset includes grayscale intensity image frames captured simultaneously using an Active Pixel Sensor (APS). Both data types were collected using the DAVIS346 camera, which integrates DVS and APS sensors.The dataset focuses on two types of defects: cracks and spalling, and includes data from both field and laboratory environments. The field dataset comprises 318 recording sequences,documenting 458 distinct cracks and 121 distinct spalling instances.The laboratory dataset includes 362 recording sequences, covering 220 distinct cracks and 308 spalling instances.Four realtime object detection models were evaluated on it to validate the dataset effectiveness.The results demonstrate the dataset robustness in enabling accurate defect detection and classification,even under challenging lighting conditions.
Semiconductor wafer defect classification is critical for ensuring high precision and yield in manufacturing. Traditional CNN-based models often struggle with class imbalances and recognition of the multiple overlapping defect types in wafer maps. To address these challenges, we propose ViT-Tiny, a lightweight Vision Transformer (ViT) framework optimized for wafer defect classification. Trained on the WM-38k dataset. ViT-Tiny outperforms its ViT-Base counterpart and state-of-the-art (SOTA) models, such as MSF-Trans and CNN-based architectures. Through extensive ablation studies, we determine that a patch size of 16 provides optimal performance. ViT-Tiny achieves an F1-score of 98.4%, surpassing MSF-Trans by 2.94% in four-defect classification, improving recall by 2.86% in two-defect classification, and increasing precision by 3.13% in three-defect classification. Additionally, it demonstrates enhanced robustness under limited labeled data conditions, making it a computationally efficient and reliable solution for real-world semiconductor defect detection.
Recent advances in defect detection use language models. Existing works enhanced the training data to improve the models' robustness when applied to semantically identical code (i.e., predictions should be the same). However, the use of semantically identical code has not been considered for improving the tools during their application - a concept closely related to metamorphic testing. The goal of our study is to determine whether we can use semantic-preserving transformations, analogue to mutation operators, to improve the performance of defect detection tools in the testing stage. We first collect existing publications which implemented semantic-preserving transformations and share their implementation, such that we can reuse them. We empirically study the effectiveness of three different ensemble strategies for enhancing defect detection tools. We apply the collected transformations on the Devign dataset, considering vulnerabilities as a type of defect, and two fine-tuned large language models for defect detection (VulBERTa, PLBART). We found 28 publications with 94 different transformations. We choose to implement 39 transformations from four of the publications, but a manual check revealed that 23 out 39 transformations change code semantics. Using the 16 remaining, correct transformations and three ensemble strategies, we were not able to increase the accuracy of the defect detection models. Our results show that reusing shared semantic-preserving transformation is difficult, sometimes even causing wrongful changes to the semantics. Keywords: defect detection, language model, semantic-preserving transformation, ensemble
Camouflaged object segmentation presents unique challenges compared to traditional segmentation tasks, primarily due to the high similarity in patterns and colors between camouflaged objects and their backgrounds. Effective solutions to this problem have significant implications in critical areas such as pest control, defect detection, and lesion segmentation in medical imaging. Prior research has predominantly emphasized supervised or unsupervised pre-training methods, leaving zero-shot approaches significantly underdeveloped. Existing zero-shot techniques commonly utilize the Segment Anything Model (SAM) in automatic mode or rely on vision-language models to generate cues for segmentation; however, their performances remain unsatisfactory. Optical flow, commonly utilized for detecting moving objects, has demonstrated effectiveness even with camouflaged entities. Our method integrates optical flow, a vision-language model, and SAM 2 into a sequential pipeline, where the output of one component provides cues for the next. Evaluated on the MoCA-Masks dataset, our approach achieves outstanding performance improvements, significantly outperforming existing zero-shot methods by raising the mean Intersection-over-Union (mIoU) from 0.273 to 0.561. Remarkably, this simple yet effective approach also surpasses supervised methods, increasing mIoU from 0.422 to 0.561. Additionally, evaluation on the MoCA-Filter dataset demonstrates an increase in the success rate from 0.628 to 0.697 when compared with FlowSAM, a supervised transfer method. A thorough ablation study further validates the individual contributions of each component.
We propose a novel, good-quality, and less demanding method for detecting knots on the surface of wooden logs using multimodal data fusion. Knots are a primary factor affecting the quality of sawn timber, making their detection fundamental to any timber grading or cutting optimization system. While X-ray computed tomography provides accurate knot locations and internal structures, it is often too slow or expensive for practical use. An attractive alternative is to use fast and cost-effective log surface measurements, such as laser scanners or RGB cameras, to detect surface knots and estimate the internal structure of wood. However, due to the small size of knots and noise caused by factors, such as bark and other natural variations, detection accuracy often remains low when only one measurement modality is used. In this paper, we demonstrate that by using a data fusion pipeline consisting of separate streams for RGB and point cloud data, combined by a late fusion module, higher knot detection accuracy can be achieved compared to using either modality alone. We further propose a simple yet efficient sawing angle optimization method that utilizes surface knot detections and cross-correlation to minimize the amount of unwanted arris knots, demonstrating its benefits over randomized sawing angles.
Small object detection (SOD) is a critical yet challenging task in computer vision, with applications like spanning surveillance, autonomous systems, medical imaging, and remote sensing. Unlike larger objects, small objects contain limited spatial and contextual information, making accurate detection difficult. Challenges such as low resolution, occlusion, background interference, and class imbalance further complicate the problem. This survey provides a comprehensive review of recent advancements in SOD using deep learning, focusing on articles published in Q1 journals during 2024-2025. We analyzed challenges, state-of-the-art techniques, datasets, evaluation metrics, and real-world applications. Recent advancements in deep learning have introduced innovative solutions, including multi-scale feature extraction, Super-Resolution (SR) techniques, attention mechanisms, and transformer-based architectures. Additionally, improvements in data augmentation, synthetic data generation, and transfer learning have addressed data scarcity and domain adaptation issues. Furthermore, emerging trends such as lightweight neural networks, knowledge distillation (KD), and self-supervised learning offer promising directions for improving detection efficiency, particularly in resource-constrained environments like Unmanned Aerial Vehicles (UAV)-based surveillance and edge computing. We also review widely used datasets, along with standard evaluation metrics such as mean Average Precision (mAP) and size-specific AP scores. The survey highlights real-world applications, including traffic monitoring, maritime surveillance, industrial defect detection, and precision agriculture. Finally, we discuss open research challenges and future directions, emphasizing the need for robust domain adaptation techniques, better feature fusion strategies, and real-time performance optimization.
Industrial Anomaly Detection (IAD) is critical to ensure product quality during manufacturing. Although existing zero-shot defect segmentation and detection methods have shown effectiveness, they cannot provide detailed descriptions of the defects. Furthermore, the application of large multi-modal models in IAD remains in its infancy, facing challenges in balancing question-answering (QA) performance and mask-based grounding capabilities, often owing to overfitting during the fine-tuning process. To address these challenges, we propose a novel approach that introduces a dedicated multi-modal defect localization module to decouple the dialog functionality from the core feature extraction. This decoupling is achieved through independent optimization objectives and tailored learning strategies. Additionally, we contribute to the first multi-modal industrial anomaly detection training dataset, named Defect Detection Question Answering (DDQA), encompassing a wide range of defect types and industrial scenarios. Unlike conventional datasets that rely on GPT-generated data, DDQA ensures authenticity and reliability and offers a robust foundation for model training. Experimental results demonstrate that our proposed method, Explainable Industrial Anomaly Detection Assistant (EIAD), achieves outstanding performance in defect detection and localization tasks. It not only significantly enhances accuracy but also improves interpretability. These advancements highlight the potential of EIAD for practical applications in industrial settings.
Visual Quality Inspection plays a crucial role in modern manufacturing environments as it ensures customer safety and satisfaction. The introduction of Computer Vision (CV) has revolutionized visual quality inspection by improving the accuracy and efficiency of defect detection. However, traditional CV models heavily rely on extensive datasets for training, which can be costly, time-consuming, and error-prone. To overcome these challenges, synthetic images have emerged as a promising alternative. They offer a cost-effective solution with automatically generated labels. In this paper, we propose a pipeline for generating synthetic images using domain randomization. We evaluate our approach in three real inspection scenarios and demonstrate that an object detection model trained solely on synthetic data can outperform models trained on real images.
Automatic visual inspection using machine learning-based methods plays a key role in achieving zero-defect policies in industry. Research on anomaly detection approaches is constrained by the availability of datasets that represent complex defect appearances and imperfect imaging conditions, which are typical to industrial processes. Recent benchmarks indicate that most publicly available datasets are biased towards optimal imaging conditions, leading to an overestimation of the methods' applicability to real-world industrial scenarios. To address this gap, we introduce the Industrial Screen Printing Anomaly Detection dataset (ISP-AD). It presents challenging small and weakly contrasted surface defects embedded within structured patterns exhibiting high permitted design variability. To the best of our knowledge, it is the largest publicly available industrial dataset to date, including both synthetic and real defects collected directly from the factory floor. In addition to the evaluation of defect detection performance of recent unsupervised anomaly detection methods, experiments on a mixed supervised training approach, incorporating both synthesized and real defects, were conducted. Even small amounts of injected real defects prove beneficial for model generalization. Furthermore, starting from training on purely synthetic defects, emerging real defective samples can be efficiently integrated into subsequent scalable training. Research findings indicate that supervision by means of both synthetic and accumulated real defects can complement each other, meeting demanded industrial inspection requirements such as low false positive rates and high recall. The presented unsupervised and supervised dataset splits are designed to emphasize research on unsupervised, self-supervised, and supervised approaches, enhancing their applicability to industrial settings.
Automated defect detection in industrial manufacturing is essential for maintaining product quality and minimizing production errors. In air disc brake manufacturing, ensuring the precision of laser-engraved nameplates is crucial for accurate product identification and quality control. Engraving errors, such as misprints or missing characters, can compromise both aesthetics and functionality, leading to material waste and production delays. This paper presents a proof of concept for an AI-driven computer vision system that inspects and verifies laser-engraved nameplates, detecting defects in logos and alphanumeric strings. The system integrates object detection using YOLOv7, optical character recognition (OCR) with Tesseract, and anomaly detection through a residual variational autoencoder (ResVAE) along with other computer vision methods to enable comprehensive inspections at multiple stages. Experimental results demonstrate the system's effectiveness, achieving 91.33% accuracy and 100% recall, ensuring that defective nameplates are consistently detected and addressed. This solution highlights the potential of AI-driven visual inspection to enhance quality control, reduce manual inspection efforts, and improve overall manufacturing efficiency.
In industrial anomaly detection (IAD), accurately identifying defects amidst diverse anomalies and under varying imaging conditions remains a significant challenge. Traditional approaches often struggle with high false-positive rates, frequently misclassifying normal shadows and surface deformations as defects, an issue that becomes particularly pronounced in products with complex and intricate surface features. To address these challenges, we introduce PA-CLIP, a zero-shot anomaly detection method that reduces background noise and enhances defect detection through a pseudo-anomaly-based framework. The proposed method integrates a multiscale feature aggregation strategy for capturing detailed global and local information, two memory banks for distinguishing background information, including normal patterns and pseudo-anomalies, from true anomaly features, and a decision-making module designed to minimize false positives caused by environmental variations while maintaining high defect sensitivity. Demonstrated on the MVTec AD and VisA datasets, PA-CLIP outperforms existing zero-shot methods, providing a robust solution for industrial defect detection.
Metal defect detection is critical in industrial quality assurance, yet existing methods struggle with grayscale variations and complex defect states, limiting its robustness. To address these challenges, this paper proposes a Self-Adaptive Gamma Context-Aware SSM-based model(GCM-DET). This advanced detection framework integrating a Dynamic Gamma Correction (GC) module to enhance grayscale representation and optimize feature extraction for precise defect reconstruction. A State-Space Search Management (SSM) architecture captures robust multi-scale features, effectively handling defects of varying shapes and scales. Focal Loss is employed to mitigate class imbalance and refine detection accuracy. Additionally, the CD5-DET dataset is introduced, specifically designed for port container maintenance, featuring significant grayscale variations and intricate defect patterns. Experimental results demonstrate that the proposed model achieves substantial improvements, with [email omitted] gains of 27.6\%, 6.6\%, and 2.6\% on the CD5-DET, NEU-DET, and GC10-DET datasets.
As industrial products become abundant and sophisticated, visual industrial defect detection receives much attention, including two-dimensional and three-dimensional visual feature modeling. Traditional methods use statistical analysis, abnormal data synthesis modeling, and generation-based models to separate product defect features and complete defect detection. Recently, the emergence of foundation models has brought visual and textual semantic prior knowledge. Many methods are based on foundation models (FM) to improve the accuracy of detection, but at the same time, increase model complexity and slow down inference speed. Some FM-based methods have begun to explore lightweight modeling ways, which have gradually attracted attention and deserve to be systematically analyzed. In this paper, we conduct a systematic survey with comparisons and discussions of foundation model methods from different aspects and briefly review non-foundation model (NFM) methods recently published. Furthermore, we discuss the differences between FM and NFM methods from training objectives, model structure and scale, model performance, and potential directions for future exploration. Through comparison, we find FM methods are more suitable for few-shot and zero-shot learning, which are more in line with actual industrial application scenarios and worthy of in-depth research.
The normal operation of power equipment plays a critical role in the power system, making anomaly detection for power equipment highly significant. This paper proposes an improved YOLOv7x-based anomaly detection algorithm for power equipment. First, the ACmix convolutional mixed attention mechanism module is introduced to effectively suppress background noise and irrelevant features, thereby enhancing the network's feature extraction capability. Second, the Biformer attention mechanism is added to the network to strengthen the focus on key features, improving the network's ability to flexibly recognize feature images. Finally, to more comprehensively evaluate the relationship between predicted and ground truth bounding boxes, the original loss function is replaced with the MPDIoU function, addressing the issue of mismatched predicted bounding boxes. The improved algorithm enhances detection accuracy, achieving a [email omitted]/% of 93.5% for all target categories, a precision of 97.1%, and a recall of 97%.
In the field of integrated circuit manufacturing, the detection and classification of nanoscale wafer defects are critical for subsequent root cause analysis and yield enhancement. The complex background patterns observed in scanning electron microscope (SEM) images and the diverse textures of the defects pose significant challenges. Traditional methods usually suffer from insufficient data, labels, and poor transferability. In this paper, we propose a novel few-shot learning approach, SEM-CLIP, for accurate defect classification and segmentation. SEM-CLIP customizes the Contrastive Language-Image Pretraining (CLIP) model to better focus on defect areas and minimize background distractions, thereby enhancing segmentation accuracy. We employ text prompts enriched with domain knowledge as prior information to assist in precise analysis. Additionally, our approach incorporates feature engineering with textual guidance to categorize defects more effectively. SEM-CLIP requires little annotated data, substantially reducing labor demands in the semiconductor industry. Extensive experimental validation demonstrates that our model achieves impressive classification and segmentation results under few-shot learning scenarios.
The inspection of local flaws (LFs) in Steel Wire Ropes (SWRs) is crucial for ensuring safety and reliability in various industries. Magnetic Flux Leakage (MFL) imaging is commonly used for non-destructive testing, but its effectiveness is often hindered by the combined effects of inspection speed and sampling rate. To address this issue, the impacts of inspection speed and sampling rate on image quality are studied, as variations in these factors can cause stripe noise, axial compression of defect features, and increased interference, complicating accurate detection. We define the relationship between inspection speed and sampling rate as spatial sampling resolution (SSR) and propose an adaptive SSR target-feature-oriented (AS-TFO) method. This method incorporates adaptive adjustment and pyramid image fusion techniques to enhance defect detection under different SSR scenarios. Experimental results show that under high SSR scenarios, the method achieves a precision of 94.73% and a recall of 96.77%. It remains robust under low SSR scenarios with a precision of 94.30% and recall of 97.32%. The overall results show that the proposed method outperforms conventional approaches, achieving state-of-the-art performance. This improvement in detection accuracy and robustness is particularly valuable for handling complex inspection conditions, where inspection speed and sampling rate can vary significantly, making detection more robust and reliable in industrial settings.