Case Study: a leading north american wallboard manufacturer achieves real-time quality control with RoviSys AI vision

a leading North American wallboard manufacturer deploys AI quality control in less than 6 months with RoviSys

A leading North American wallboard manufacturer faced significant production inefficiencies due to a lab-testing bottleneck for quality control. Their traditional process of manually cutting and analyzing samples created a 10-minute visibility gap, which was untenable at their production rate of roughly 2,000 sheets per hour. This put premium product at risk and increased the chance of creating unsellable material. They partnered with RoviSys to operationalize a computer vision and machine learning solution to eliminate this bottleneck.

RoviSys designed and implemented a scalable AI solution featuring computer vision for real-time feature extraction and a neural network classifier for grade prediction. This system provided immediate quality feedback, closed the production-to-quality gap, and was delivered in less than six months under budget. The results allowed the manufacturer to independently roll out the solution to over 12 additional sites after the initial deployment at five facilities, using materials costing under $50 per station. RoviSys successfully bridged the gap between a data science concept and a production-ready system.