Visual inspection is one of the oldest and most widely used methods for checking the quality of manufacturing processes, products, components, or materials across various industries.
Historically, it involves using the human eye and intelligence — sometimes with the help of simple tools like a magnifying glass, as well as pen and paper, these days replaced with a visual inspection app in your own smartphone in your pocket. Or other devices like advanced cameras, drones, and AI —to look for defects, irregularities, or inconsistencies.
The goal is to catch any issues early, so they can be fixed before issues increase costs, lower quality or, even worse, leads to product deficiencies that get passed on when the product moves on to the next stage of the supply chain or, worse of all, reaches the end-consumer.
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How Visual Inspections Work
In many industries, visual inspections are the first line of defense in quality control. They are valued for their simplicity, speed, and effectiveness. Whether it’s a product coming off a production line, a piece of equipment in a factory, or a building structure, visual inspections help ensure that standards are met and that any defects are caught early.
Good lighting is important, as it helps the employee doing the inspection see any flaws clearly. The employee then examines the item closely, looking for issues such as cracks, scratches, or misalignment that could affect its quality or safety.
Pro-tip: In the food and other industries, we use the term non-conformity to describe issues.
Different Types of Visual Inspections
Visual inspections are used in many different industries to check for problems and make sure things are working as they should. Even though the basic idea is the same — looking closely at something to spot defects— how visual inspections are done can vary depending on the industry and the specific needs of the job.
1. Direct Visual Inspection
Direct visual inspection is the simplest and most common type. It involves an employee looking directly at the object or area that needs to be checked. This can be done with the naked eye or with the help of simple tools like magnifying glasses. Direct visual inspections are used in many industries, such as manufacturing, where workers might check products on an assembly line for defects like scratches, dents, or incorrect assembly.
In construction, direct visual inspections might involve checking the structural integrity of a building or looking for visible cracks in walls or foundations. In food production, workers might inspect food items to make sure they are properly labeled, free from contamination, and meet quality standards.
2. Indirect Visual Inspection
Sometimes, it’s not possible to see the area that needs to be inspected directly. In these cases, employees use tools like mirrors, cameras, or borescopes (tiny cameras on flexible tubes) to look at hard-to-reach places. This type of inspection is common in industries like aerospace or automotive, where parts of an engine or machinery might be hidden from view. Indirect visual inspections help ensure that even areas that are difficult to see are checked for defects or wear and tear.
3. Automated Visual Inspection
With advancements in technology, some industries have started using automated visual inspection systems. These systems use cameras, sensors, and software to automatically check products for defects. For example, in electronics manufacturing, automated systems can quickly scan circuit boards for flaws that are too small or numerous for a person to check by hand. While automated systems are fast and can handle large volumes, they can be expensive to set up and maintain.
4. AI-Powered Visual Inspection
AI-powered visual inspection takes automation a step further by using artificial intelligence and machine learning. These systems can learn from past inspections and improve over time. They are particularly useful for spotting subtle defects that might be missed by traditional methods. While AI-powered systems are cutting-edge, they are still developing and can be costly to implement. Additionally, they require large amounts of data to function effectively, which may not be practical for all companies.
Why Manual Visual Inspections Still Matter
In recent years, advancements in technology have significantly changed the way visual inspections are done. Artificial Intelligence (AI) and other automated systems are now being used in various industries to improve the accuracy and speed of inspections. While these technologies offer many benefits, there are still important reasons why manual visual inspections, especially those done with tools like Inspectle, are preferred in certain situations, particularly in industries like food production.
How AI and Automation Work in Visual Inspections
AI-powered visual inspection systems use cameras, sensors, and advanced software to automatically detect defects or irregularities in products. These systems can process large amounts of data quickly, making them ideal for industries like electronics, automotive, and pharmaceuticals, where speed and precision are important. For example, in a factory producing microchips, an AI system might be used to scan thousands of chips per minute, identifying even the smallest flaws that human eyes might miss.
Automated systems also reduce the chances of human error. They don’t get tired, and their performance doesn’t vary from day to day. This makes them reliable for repetitive tasks that require consistent results. Moreover, AI systems can learn from data, meaning they can improve over time as they process more information.
The Limits of AI in Visual Inspections
Despite their advantages, AI and automated systems have limitations. They are often expensive to install and maintain, which can be a barrier for smaller companies. Additionally, while AI can be very effective at identifying certain types of defects, it may struggle with more complex or unusual problems that don’t fit into its programmed patterns.
In industries like food production, where quality and safety are top priorities, human
judgment is still highly valued. Employees conducting manual visual inspections can notice subtle issues that AI might overlook, such as a slight discoloration that indicates spoilage or a minor inconsistency in packaging that could lead to a labeling error. Human inspectors are also better at understanding context, which is important when evaluating whether a defect is significant or not.
Why Manual Inspections with Tools Like Inspectle Are Still Important
While AI and automation are advancing, manual visual inspections remain essential, especially in industries where quality and safety are critical. Tools like Inspectle enhance these inspections by making them more efficient and reliable. With Inspectle, employees can take photos of issues on the spot, add notes, and quickly log the information. This approach combines the strengths of human observation with the convenience of modern technology, ensuring that inspections are thorough and that problems are addressed promptly.
Manual inspections also allow for flexibility. If an unexpected issue arises, a human inspector can assess the situation and make a judgment call that a machine might not be able to make. For this reason, many companies prefer a balanced approach, using both AI and human inspectors to achieve the best results.
A Better Way to Do Visual Inspections with Inspectle
Visual inspections have become easier and more effective with the help of technology, and tools like Inspectle make this process simple for everyone involved, from quality teams to production and maintenance workers. Unlike traditional inspections that rely only on what employees see with their eyes, Inspectle combines human observation with smart software to help find and fix problems faster.
Doing Visual Inspections with Inspectle
With Inspectle, visual inspections start with employees using their mobile devices to take pictures of any issues they notice. For example, if an employee spots a crack in a machine, a dirty surface, or any other problem, they can quickly snap a photo, add notes, and log the issue right then and there.
Inspectle’s software automatically organizes these photos and notes, creating a clear record of what was found, when it was found, and what actions were taken to fix it. By using pictures instead of just words, Inspectle makes it easier to spot and solve problems quickly.
If an issue needs urgent attention, like a food safety risk or equipment breakdown, documenting it with Inspectle helps to alert the right people immediately. This way, teams can act fast, stopping small issues from becoming bigger ones.
The Benefits of Using Inspectle for Visual Inspections
Inspectle makes visual inspections faster, more accurate, and easier for everyone. Traditional inspections might involve filling out forms, writing reports, and then following up later. Inspectle simplifies all this by using visual data and automating much of the work. Employees can focus on finding and fixing problems, while the software handles the organization, alerts, and record-keeping.
For industries like food production, where safety and quality are very important, having a system like Inspectle helps keep everything running smoothly. It ensures that inspections are thorough and consistent, leading to better results. Try it for free!
About the Author: Robert Jakobson
Robert Jakobson has worked in the manufacturing industry since 2010. With over a decade of experience in B2B marketing, he specializes in helping companies improve their operations with software and hardware solutions. His deep knowledge of the industry and passion for technology make him a trusted expert. Robert’s experience ranges from product development to marketing, giving him valuable insights into how businesses can use tools like the Inspectle Food Safety Inspection software to stay compliant and improve their processes.