Visual defect detection in industrial glass manufacturing remains a critical challenge due to the low frequency of defective products, leading to imbalanced datasets that limit the performance of deep learning models and computer vision systems. This paper presents a novel approach using Denoising Diffusion Probabilistic Models (DDPMs) to generate synthetic defective glass product images for data augmentation, effectively addressing class imbalance issues in manufacturing quality control and automated visual inspection. The methodology significantly enhances image classification performance of standard CNN architectures (ResNet50V2, EfficientNetB0, and MobileNetV2) in detecting anomalies by increasing the minority class representation. Experimental results demonstrate substantial improvements in key machine learning metrics, particularly in recall for defective samples across all tested deep neural network architectures while maintaining perfect precision. The most dramatic improvement was observed in ResNet50V2's overall classification accuracy, which increased from 78 percent to 93 percent when trained with the augmented data. This work provides a scalable, cost-effective approach to enhancing automated defect detection in glass manufacturing that can potentially be extended to other industrial quality assurance systems and industries with similar class imbalance challenges.
Industrial defect segmentation is critical for manufacturing quality control. Due to the scarcity of training defect samples, few-shot semantic segmentation (FSS) holds significant value in this field. However, existing studies mostly apply FSS to tackle defects on simple textures, without considering more diverse scenarios. This paper aims to address this gap by exploring FSS in broader industrial products with various defect types. To this end, we contribute a new real-world dataset and reorganize some existing datasets to build a more comprehensive few-shot defect segmentation (FDS) benchmark. On this benchmark, we thoroughly investigate metric learning-based FSS methods, including those based on meta-learning and those based on Vision Foundation Models (VFMs). We observe that existing meta-learning-based methods are generally not well-suited for this task, while VFMs hold great potential. We further systematically study the applicability of various VFMs in this task, involving two paradigms: feature matching and the use of Segment Anything (SAM) models. We propose a novel efficient FDS method based on feature matching. Meanwhile, we find that SAM2 is particularly effective for addressing FDS through its video track mode. The contributed dataset and code will be available at: https://github.com/liutongkun/GFDS.
This expository paper introduces a simplified approach to image-based quality inspection in manufacturing using OpenAI's CLIP (Contrastive Language-Image Pretraining) model adapted for few-shot learning. While CLIP has demonstrated impressive capabilities in general computer vision tasks, its direct application to manufacturing inspection presents challenges due to the domain gap between its training data and industrial applications. We evaluate CLIP's effectiveness through five case studies: metallic pan surface inspection, 3D printing extrusion profile analysis, stochastic textured surface evaluation, automotive assembly inspection, and microstructure image classification. Our results show that CLIP can achieve high classification accuracy with relatively small learning sets (50-100 examples per class) for single-component and texture-based applications. However, the performance degrades with complex multi-component scenes. We provide a practical implementation framework that enables quality engineers to quickly assess CLIP's suitability for their specific applications before pursuing more complex solutions. This work establishes CLIP-based few-shot learning as an effective baseline approach that balances implementation simplicity with robust performance, demonstrated in several manufacturing quality control applications.
Manufacturing industries require efficient and voluminous production of high-quality finished goods. In the context of Industry 4.0, visual anomaly detection poses an optimistic solution for automatically controlled product quality with high precision. In general, automation based on computer vision is a promising solution to prevent bottlenecks at the product quality checkpoint. We considered recent advancements in machine learning to improve visual defect localization, but challenges persist in obtaining a balanced feature set and database of the wide variety of defects occurring in the production line. Hence, this paper proposes a defect localizing autoencoder with unsupervised class selection by clustering with k-means the features extracted from a pre-trained VGG16 network. Moreover, the selected classes of defects are augmented with natural wild textures to simulate artificial defects. The study demonstrates the effectiveness of the defect localizing autoencoder with unsupervised class selection for improving defect detection in manufacturing industries. The proposed methodology shows promising results with precise and accurate localization of quality defects on melamine-faced boards for the furniture industry. Incorporating artificial defects into the training data shows significant potential for practical implementation in real-world quality control scenarios.
Digitization has led to smart, connected technologies be an integral part of businesses, governments and communities. For manufacturing digitization, there has been active research and development with a focus on Cloud Manufacturing (CM) and the Industrial Internet of Things (IIoT). This work presents a computer vision toolkit (CV Toolkit) for non-invasive digitization of the factory floor in line with Industry 4.0 requirements for factory data collection. Currently, technical challenges persist towards digitization of legacy systems due to the limitation for changes in their design and sensors. This novel toolkit is developed to facilitate easy integration of legacy production machinery and factory floor artifacts with the digital and smart manufacturing environment with no requirement of any physical changes in the machines. The system developed is modular, and allows real-time monitoring of production machinery. Modularity aspect allows the incorporation of new software applications in the current framework of CV Toolkit. To allow connectivity of this toolkit with manufacturing floors in a simple, deployable and cost-effective manner, the toolkit is integrated with a known manufacturing data standard, MTConnect, to "translate" the digital inputs into data streams that can be read by commercial status tracking and reporting software solutions. The proposed toolkit is demonstrated using a mock-panel environment developed in house at the University of Cincinnati to highlight its usability.
Quality control is an essential process in manufacturing to make the product defect-free as well as to meet customer needs. The automation of this process is important to maintain high quality along with the high manufacturing throughput. With recent developments in deep learning and computer vision technologies, it has become possible to detect various features from the images with near-human accuracy. However, many of these approaches are data intensive. Training and deployment of such a system on manufacturing floors may become expensive and time-consuming. The need for large amounts of training data is one of the limitations of the applicability of these approaches in real-world manufacturing systems. In this work, we propose the application of a Siamese convolutional neural network to do one-shot recognition for such a task. Our results demonstrate how one-shot learning can be used in quality control of steel by identification of defects on the steel surface. This method can significantly reduce the requirements of training data and can also be run in real-time.