Assembly verification uses cameras at assembly stations to confirm every component is present, is the right variant, faces the right way and is fully seated before the product moves on. It is automated error-proofing, or poka-yoke, with a photo record of every unit.
Assembly verification is the check that an assembly has been built correctly: every part there, the right part for this model, facing the right way and properly fitted. Done by people at the end of the line, it is slow and misses things; done by cameras at each station, it catches errors while they are cheap to fix.
In lean manufacturing this is called poka-yoke, or mistake-proofing: designing the process so that an error cannot pass unnoticed.
The station reads the product serial or order so it knows which variant and which parts to expect.
Cameras capture the assembly after each critical step, from as many angles as needed.
Each component is checked for presence, correct type, orientation and seating.
A failure lights the station and blocks the next step until the mistake is corrected.
Images and results are stored against the serial number for traceability and warranty claims.
Simple, fast tools confirm that a component, screw, clip or label is where it should be.
Pattern matching and colour tools distinguish look-alike parts, and the expected variant is taken from the order.
Handles features that vary in appearance, such as cables, hoses and flexible parts, where rules are hard to write.
The vision result is wired to the station controller, so a failed check physically prevents the next operation.
Two example project scopes showing how the station, the checks and the outputs are defined. Every plant is different, so the final configuration is confirmed after a feasibility study on your own parts.
The situation: A harness maker has had warranty returns traced to unseated connectors.
The situation: A spare parts packer ships kits and receives complaints about missing items.
Industrial cameras, lenses, line-scan cameras and code readers are available through our machine vision catalog, quoted with delivery to Sri Lanka. We select the hardware for your application during the feasibility study.
Browse the hardware catalogEvery product, surface and line behaves differently under a camera, so every project starts with evidence from your own material.
A site visit to understand your product, line speed, quality criteria and where the check should sit.
We image your good and defective samples and show what the system can reliably detect. This is the go or no-go.
One station on one line, running beside your inspectors until results match and your team trusts them.
More lines, integration with your PLC and systems, and local support from our Sri Lankan engineering team.
Industrial code reading and traceability: read and grade barcodes, QR and Data Matrix codes to ISO/IEC 15415 and 15416, verify printed date and lot codes with OCR, and reject every unreadable or wrong code.
Automated optical inspection for electronics: solder paste inspection, pre and post-reflow AOI, through-hole and conformal coating checks. Find missing, wrong, misaligned and reversed parts and solder faults to IPC-A-610.
Sort fabric rolls, cut panels and washed garments into buyer shade bands with CIELAB measurement and 555 codes.
Every machine vision application we design and build, in one place.
Poka-yoke is a Japanese term meaning mistake-proofing. It describes designing a process so that errors are prevented or detected immediately. A vision check with a station interlock is a common poka-yoke in assembly.
Usually, yes, using shape, colour, markings or labels. The system also knows which variant is being built from the order or serial number, so it checks for the specific part that should be there.
No. A check takes a fraction of a second. Operators typically see a green or red light and only act when something is wrong.
Yes. Flexible parts vary in appearance, so deep learning is often used to recognise correct routing and seating where rule-based tools struggle.
An image archive by serial number shows exactly how each unit was built. It settles warranty disputes quickly and helps engineers trace field failures to their cause.
Tell us what you need to check and share some good and faulty samples. We will show you what a camera can reliably see before you commit to anything.
Photographs show representative plants and equipment, not Cerox installations or client sites. Diagrams by Cerox Engineering. Photo credits, via Wikimedia Commons: Car body inspection by General Motors, CC BY 3.0; Robotic assembly line by GillyBerlin, CC BY 2.0.