Assembly Verification

Ensuring Perfect Component Assembly and Positioning

Overview.ai's Vision System is critical for ensuring components are correctly assembled, seated, and positioned — preventing costly errors and ensuring product functionality from the first unit off the line.

100% Inspection Coverage

<1s Cycle Time
0 Missed Defects

Proven Solutions

Key Applications

Soft Seated Connectors Inspection

We help automotive OEMs solve the long-standing problem of identifying loosely fitted or "soft seated" connectors, where a component is not fully or properly seated or engaged. It overcomes the complexities of inspecting these subtle defects on a continuously moving assembly line by using an advanced software auto-trigger mechanism for precise image capture. Its unparalleled AI algorithms can process and analyze hundreds of inspection points concurrently, even at different angles, ensuring comprehensive coverage and high-confidence checks to prevent electrical failures, fluid leaks, and safety concerns.

100+ Inspection Points
Auto-Trigger
Moving Assembly Line

Speaker Panel Gap Detection

For automotive suppliers manufacturing speaker panels, the OV20i identifies gaps that prevent a snug fit in the corner, which is crucial for good acoustic performance. The system can identify correct parts, defective parts, and the precise location of defects for fixing — even though mesh panels make identification difficult and gaps can appear in multiple locations. Overview AI achieved 97% accuracy with only 6 training images and in less than 30 minutes.

97% Accuracy
6 Training Images
30 Min Setup

Black Clips in Foam Molds Presence & Placement

A major automotive supplier uses Overview AI to detect the presence and correct placement of black clips in foam molds. This challenge is amplified by eight different types of molds and altering mold appearance due to resin build-up. The OV20i implemented a classification and segmentation recipe, achieving 100% accuracy in presence/absence tests with a handful of samples — and with additional training, detected incorrectly seated clips. The system proved robust to vibrations and resin build-up that had caused prior systems to fail.

100% Accuracy
8 Mold Types
Vibration-Robust

Half Shaft Soft-Set Detection

For a major automotive OEM, the OV20i tackles the challenging inspection of detecting a soft-set condition in half shafts. These parts are often located deep inside the vehicle and partially obstructed, making them difficult to access visually. Overview AI trained a classification and segmentation recipe with minimal training data to quickly assess pass/fail scenarios, identify correctly fit and soft-set conditions, and incorporate thresholds with additional training to reduce overkill and allow for part correction.

Pass/Fail
Obstructed Views
Threshold Tuning

Loose Bolts in Engine Kits

The OV20i provides a solution for detecting loose bolts in engine kits, despite challenges like varying kit colors, shiny and oily finishes, and bolts often being hidden behind edges or varying significantly in size and orientation. Overview AI quickly trained and tested a segmentation recipe that could identify bolts in obstructed views, avoid reflections, and deal with multiple finishes — correctly identifying them in 47 out of 50 test cases with over 50 samples.

94% Detection Rate
Oily & Shiny Finishes
Obstructed Bolts

Seat Belt Cover Presence

For automotive suppliers manufacturing seats and belts, the OV20i implements a classifier recipe to identify the presence or absence of seat belt covers, addressing issues that led to A-ranked OEM defects. This inspection is particularly challenging due to black-on-black detection, variable lighting and placement, and the wide angle required. Leveraging its aligner tool to handle shifts and rotations, the system achieved 100% accuracy across all samples with only 10 images per component and 15 minutes of setup time.

100% Accuracy
10 Images
15 Min Setup

Seatbelt Guide Gap Length Measurement

The OV20i assists automotive suppliers with customer inspections for the gap in seatbelt guides, which previously led to escapes and chargebacks due to existing vision systems struggling with the required precision. Overview AI trained a classifier recipe that directly measures gap size and classifies pass/fail. With just 7 images and less than 30 minutes of training, the system accurately measured the gap — followed by Node-Red logic to define a clear passing threshold for high performance.

7 Training Images
Gap Measurement
Node-Red Logic

Breaker Base Inspection (Pitting, Flashing Lights, Inserts)

For a major electrical components manufacturer, Overview AI implemented a segmentation recipe to consolidate manual inspection of Breaker Bases. The solution addressed challenges like varied inspection needs, low contrast parts, and subtle pieces — allowing for the confirmation of flashing lights, detection of pitting, and inspection of small inserts within a single image. Initial issues were resolved through additional imaging and training to further reduce overkill.

3-in-1 Inspection
Low Contrast Parts
Segmentation Recipe

Label Placement Verification (Medical Electronics)

Building on its success in contaminant detection, Overview AI extended a recipe for Valtronic to include identifying the correct placement of labels — allowing a single camera and program to manage both inspection issues simultaneously. This helps medical electronics manufacturers ensure proper labeling compliance and reduce quality control overhead.

Dual Inspection
Single Camera
Medical Compliance

Capabilities

Multi-Region Inspection
PLC Integration
100+ Point Checks
Custom Logic Rules

The Overview AI Advantage

Why Manufacturers Choose Overview AI

Purpose-built for high-stakes assembly verification where every connection matters.

Hundreds of Points

Inspect hundreds of regions of interest concurrently, even at different angles, in a single pass.

15-Minute Setup

Achieve 100% accuracy with as few as 7–10 training images and under 30 minutes of setup time.

Seamless Integration

Integrates with PLC, Node-Red logic, and existing line controls for automated pass/fail decisions.

From Install to Production in Hours

No months-long integrations. No dedicated vision specialists. Just fast, accurate inspection.

Install & Configure

Mount the camera, connect to your network via any browser — no software installs, no license keys. Full system operational in under 2 hours.

< 2 Hours

Train with Real Images

Capture as few as 5 production images, label defects in-browser, and train a production-grade model. Built-in augmentation generates 10x more training data automatically.

5–50 Images

Deploy & Retrain

Push the model to the camera — no export steps, no IT tickets. Retrain on new edge cases from the production floor in under 1 hour, zero downtime.

< 1 Hr Retrain

Built for the Factory Floor

Enterprise-grade hardware and software designed for 24/7 industrial operation.

21–70 TOPS AI Compute
NVIDIA-powered on-device processing. No cloud dependency.
100K+ On-Device Images
Store weeks of production data directly on each camera.
3 Native Protocols
EtherNet/IP, Profinet, Modbus TCP — no middleware needed.
IP55 Industrial Rated
IATF 16949, AS9100, ISO 13485, IEC 62443 certified.

Node-RED on Every Camera

Visual programming for PLC triggers, reject mechanisms, data logging, and MES/ERP integration via REST APIs.

Custom Dashboards

Build operator, engineer, and management views with standard HTML/CSS/JS. Access from any browser on the network.

Haystack Discovery

Surface unknown defects and outliers automatically. Retrain to catch them — no vendor involvement required.

Ready to Automate Assembly Verification?

See how Overview AI vision deployments drive real results in days, not months.