AI-powered machine vision

An eye on every part, every count, every rule.

KVAR Vision Solutions put an AI camera where a person cannot watch every second — inspecting quality, counting and identifying parts, reading codes and text, checking that the right component is in the right place, and watching that safety rules are followed. It decides in real time, on the edge, and acts: pass or reject, count, log, alert. One camera, trained to your job.

100% inspection, not a sample. The camera never tires, never blinks, and evidences every decision — so the defect, the miscount and the near-miss are caught the moment they happen.

One platform, six kinds of watching

The same edge-AI camera and software, trained to whichever job the line needs — and more than one at a time.

CountParts, boxes, people — automatic object counting

InspectQuality & defect check — presence, surface, dimension

IdentifyPattern, shape, colour & orientation recognition

Verify placementRight component, right place, right way round

ReadOCR & code reading — text, batch, barcode, QR

Watch safetyPPE / helmet, line-crossing, restricted zones

Why vision, why on the edge

👁

100% inspection

Every unit checked, not a sample — the escape that a random check would miss is caught.

⚡

Real-time on the edge

The decision is made at the camera in milliseconds — fast enough to reject on the line, no cloud round-trip.

📷

Evidence for every event

Each pass, reject or alert is imaged and logged — full traceability and proof, not just a number.

🔄

Trainable to your job

Trained on your parts and your defects; retrained as products change — not locked to one fixed rule.

Where it runs

Automobile & auto-componentElectronics & EMSPharma & healthcare Food & beveragePackaging & printingWarehousing & logistics Construction & sites (safety)General manufacturing

What it sees

Six jobs, one camera

Each capability runs on its own or together on the same feed — count and inspect and read, all at once.

🔢

Counting & object counting

Counts parts, packs, boxes or people as they pass — accurately, at line speed, with no hand-tally.

e.g. pieces per box, output per shift, boxes on a pallet, footfall at a gate.

✅

Quality & defect check

Checks the part is present, complete and correct — missing features, surface defects, scratches, cracks, wrong dimension.

e.g. missing screw, print smudge, weld defect, out-of-spec size.

🔮

Pattern & feature identification

Recognises shape, colour, orientation and pattern — to sort, grade or match against a reference.

e.g. sort by colour / type, grade by size, confirm the right variant.

🧩

Component placement

Confirms the right component is in the right position and the right way round before the next step locks it in.

e.g. PCB component present & oriented, connector seated, label square.

📄

OCR & code reading

Reads printed text, batch and date codes, serial numbers, barcodes and QR — verifies and logs them.

e.g. batch / expiry legible & correct, serial captured, barcode matches order.

🪖

People & safety compliance

Watches that safety rules are followed — PPE and helmet worn, no one crossing a line or entering a restricted zone.

e.g. helmet / vest / mask on, no line-crossing near a machine, zone intrusion alert.

💡

New job? Train it. Because the models are trained on real images, a new part or a new defect is added by teaching the system examples — not by rewriting code. The same camera that counts today can inspect placement tomorrow.

Hardware

Camera, light, brains — and a way to act

A vision job is only as good as its picture. KVAR supplies the camera, the lighting and the edge compute, and wires the result back to the line.

EDGE AI CAMERAphoto to follow

Edge AI camera

Industrial camera with on-board AI — decides at the edge, in real time
Resolution and lens chosen to the part and the working distance
Colour or mono; area or line-scan for moving product
Works on new KVAR cameras or, where suitable, your existing cameras / CCTV

LIGHTINGphoto to follow

Lighting & optics

Ring, bar, dome or backlight to make the defect stand out
Consistent lighting is what makes results repeatable
Mounting and enclosure for the line environment

EDGE CONTROLLERphoto to follow

Edge controller & I/O

Edge compute for multi-camera and heavier models
Trigger in (sensor / encoder), result out (PLC / reject actuator)
Runs on the local network — keeps working without the cloud

Andon lamp and display for vision result

ANDON / DISPLAYKVAR-built board

Andon lamp & display

Tower lamp and KVAR display show pass / fail, count and alert at the station
Reject diverter or stopper driven on a fail
Ties straight into KVAR Andon & Production Genie

A single-check station may be one camera, a light and a lamp; a full inspection cell adds multiple cameras, an edge controller and reject actuation. Basic to Premium in hardware.

Software

Train it, watch it, and keep the record

The software is where the job is defined, the live decision is shown, and every result is stored for proof and analysis.

🎓

Train & configure

Teach the model from your images, set the pass / fail rule and the regions of interest — no coding to add a new check.

📺

Live view & overlay

The feed with the decision drawn on it — what was found, where, and why it passed or failed.

🔔

Reject & alert

Drive a reject on a fail; raise an alarm, e-mail or SMS on a defect trend or a safety breach.

📊

Reports & analytics

Pass rate, defect types and Pareto, counts per shift, safety events — daily and by line, exportable.

📁

Image & event log

Every reject and alert stored with its image and time — full traceability and evidence.

🔗

Integration

Feeds KVAR Andon & Production Genie, and talks to PLC / MES for line control and OEE.

Reports & evidence, in full. First-pass yield and reject rate, defect type Pareto, count per shift and per order, OCR read / verify log, and a time-stamped image for every reject and safety event — exportable to Excel and PDF, and rolled up across lines and sites in Premium.

Editions & ROI

Basic, Advanced, Premium

Start with a single pass / fail check on one line; grow to multi-camera inspection, OCR, safety analytics and a multi-line dashboard — hardware and software together.

Basic

One check, pass / fail

A single camera doing one job — count, presence or a simple defect check — with a local pass / fail, lamp and daily count. Vision on the line from day one.

Advanced

Inspect, read & log

Adds multiple checks and cameras, OCR / code reading, defect classification, reject actuation, image logging and the full report set.

Premium

Safety & scale

Adds people & safety analytics (PPE, line-crossing, zones), multi-line / multi-site dashboards, cloud roll-up and MES / OEE integration.

Capability	Basic	Advanced	Premium
Counting / object counting	✓	✓	✓
Quality / defect check	✓	✓	✓
Pattern & placement verification	OPT	✓	✓
OCR & code reading	—	✓	✓
Multi-camera / multi-check	—	✓	✓
Reject actuation	OPT	✓	✓
Image & event logging	OPT	✓	✓
People & safety compliance	—	OPT	✓
Andon / Production Genie integration	OPT	✓	✓
Multi-line / multi-site dashboard	—	—	✓
MES / OEE & cloud integration	—	OPT	✓

✓ included OPT optional add-on — not in this edition. Priced by the number of cameras and checks, the edition, and integration. Runs as hardware, software on your cameras, or a fully integrated cell.

Return on investment

✓

Defects stopped, not shipped — 100% inspection catches the escape a sample check misses, before it reaches the customer.

✓

Counting labour saved — the camera tallies at line speed; no hand-count, no miscount.

✓

Consistent, never tires — the same judgement on the first part and the ten-thousandth, every shift.

✓

Safety incidents prevented — a missing helmet or a crossed line flagged before it becomes an accident.

✓

Evidence & traceability — an image for every reject and event; disputes settled with proof.

✓

One supplier — camera, lighting, software and Andon from the team that built them.

From a sample checked by a tired eye — to every part, every count and every rule, watched and proven.

Vision Solutions are configured to the application — the camera, lighting, models and integration are set to the part and the check. Editions and hardware are matched to the requirement, and a firm quotation is prepared against it. Camera photographs to follow. Contact KVAR Technologies for a feasibility trial on your part.