Implementing a Defect Detection and Measurement System

Defect detection involves the visual inspection of surfaces on parts, or online. This job can be dull and difficult with the potential for human error due to subjectivity and fatigue. Failure to detect surface defects can be costly in terms of brand image, delays, recalls and health and safety risks. This makes defect detection a key concern in a broad range of industries.

Implementation of a Defect Detection and Measurement System (DDMS) can drive productivity and cut costs on the production line by automatically detecting, locating and measuring defects or imperfections on the surface of parts. What makes the DDMS stand out is the ability to gather extensive data on the defect by measuring it, which in turn enables the user to spot patterns in the defects and aid in eliminating those defects. This type of automated optical inspection takes on a preventive role and can aid a company in cutting the costs that are synonymous with recalls and delays, while positively affecting their bottom line.

The Proscan Defect Detection and Management System is equipped with a high resolution camera, mounted beside a displacement sensor on a carrier to ensure impeccable accuracy. When using a DDMS there is a five step process of Identification, Categorisation, Measurement, Filtration and Take Action, as shown below.

IdentificationCategorisationMeasurementFiltrationTake Action
An ultrahigh definition camera is scanned over the entire surface of the component, taking images, identifying and recording the position of any defects in both X and Y.Evolutionary Artificial Intelligence (AI) software then examines all of the defects and groups them into user defined categoriesThe sensor then measures the chosen defects, scans them for size and compares them with preprogrammed tolerance limits.The system has been developed to detect defects as small as a few microns, whilst the AI software can be taught to ignore dust particles or defects of no interest.The defective part can then be taken out and rectified, using the vast amounts of easily accessible data gathered by the DDMS.

Scantron’s vision detection system is a 4-axis scanning system built on a granite base with linear drives used to eliminate any vibrations. The granite table floats on three anti-vibration air cylinders, whilst the whole system is housed in an aluminium framed enclosure in order to foster reliable data.


Industries that are expected to gain the most from defect detection systems such as the Proscan DDMS:


Nuclear and Defence Industry
Nuclear and Defence Industry: precision is not negotiable and the DDMS can ensure that high standards are upheld. These Manufactured parts need to hold up in high pressure environments and, if there are undetected surface defects, this can weaken the product.
Aerospace Industry
Aerospace Industry: complex manufacturing makes the likelihood of a surface defect high. These defects, if not detected, can go on to cause serious consequences within the end product.
Automotive Industry
Automotive Industry: the high level of competition means that any defects that may be linked to a brand, can greatly affect its positioning in their customers minds. Making innovative systems such as the DDMS essential in today’s highly competitive markets.
Metal and Steel Industry
Metal and Steel Industry: high energy costs of production mean that surface defects can cause undue expenses as well as delays. DDMS can not only detect the defects, but by measuring them, it can highlight patterns that may lead to the cause of the problem, reducing costs in the long run.

The PROSCAN DDMS vision inspection system

As we have seen, deploying a suitable vision inspection system for the purposes of defect detection can positively influence a company’s bottom line. This is why Scantron has introduced the PROSCAN DDMS to its list of products. The PROSCAN DDMS eliminates subjectivity by physically measuring and automatically grading defects to give repeatable measurements. The measurement of these defects makes the PROSCAN DDMS stand out from other defect tracking systems as it not only enables companies to be aware of the defect but also gather invaluable information about the defect in order to help rectify the problem.

Benefits of measuring the defect

  • More extensive data.
  • Increase ability to rectify defect.
  • Able to spot patterns in the defects, (AI Software) and Compare defect depth and volume to programmed tolerances and reject where appropriate.

The PROSCAN defect detection system for quality assurance is intended to be implemented in the early stages of production. This ensures defects are caught as soon as possible to prevent further resources being used on a defective part.

The PROSCAN DDMS can measure a range of defects:-


The PROSCAN performs defect detection on a wide variety of material types:-

  • Soft (foods, rubber, replica material etc.)
  • Solid (metals, wood, glass etc.)
  • Polished (lenses, mirrors etc.)
  • Transparent (Glass, plastic etc.)

It’s also suitable for use in various workplaces:-

  • Work shop
  • Laboratory environment
  • On-line or off-line production

Scantron’s defect detection system can be tailored to fit your specific requirements; so if the PROSCAN DDMS does not match precisely what you are looking for in an automated optical inspection solution, get in touch to discuss your specific requirements with us.