PCI Elektronik case study: AI visual inspection on 2 production lines in Batam
PCI Elektronik, a Celestica company, runs INDUSIA's AI visual inspection on 2 production lines in Batam. It checks both PCB sides per cycle at ≥95% accuracy.
Published
- Production lines in Batam running AI inspection
- 2 lines
- Inspection accuracy on PCBs
- ≥95%
- Both PCB sides checked in one cycle
- 2 sides
- PCI has produced in Indonesia
- Since 1990
About the client
Electronics manufacturer, a Celestica company (Singapore and Canada). Founded 1971, producing in Indonesia since 1990, with a plant in Batam.
Who is PCI Elektronik and what does it make in Batam?
PCI Elektronik is an electronics manufacturer and part of Celestica, with operations in Singapore and Canada. PCI was founded in 1971 and has produced in Indonesia since 1990. INDUSIA's AI visual inspection runs on 2 of its production lines in Batam.
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A manufacturer of printed circuit board assemblies (PCBA) depends on every board leaving the line in good condition. Quality checks run at several points, and visual inspection is one of the most important.
PCI Elektronik is the first factory to run INDUSIA's AI visual inspection. The company name and logo appear here with its agreement.
What problem did visual inspection of PCBs have to solve?
Inspecting printed circuit boards by eye is slow and tiring. A person checks one side at a time, and attention drops over a long shift. INDUSIA's AI visual inspection checks both sides the same way every time, and passes only the real doubts to a person.
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Boards are small and dense, and defects can be tiny. Machines that flag defects on the SMT line also flag many boards that are in fact good, which sends extra work back to the operator.
PCI needed an inspection step that is consistent, covers both sides, and can learn new defects without calling a data scientist each time.
The inspection was therefore designed as a consistent system that factory people can teach themselves, not one that needs the vendor for every change.
What did INDUSIA build for PCI's AI visual inspection?
INDUSIA designed and built the inspection machine itself, as an AOI machine for PCB. Cameras and AI check side A, a mechanical holder flips the board with no robot arm, the AI checks side B, and the board is sorted into OK or NG. It works with any brand of high-resolution camera.
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Because the AI works on any brand of high-resolution camera, PCI is not tied to one camera vendor. INDUSIA builds the machine and the software together, so one team stands behind both.
The AI reaches ≥95% accuracy on PCBs. The table below shows the main parts of the system and what each one does.
| Part | What it does |
|---|---|
| High-resolution camera (any brand) | Takes the board image for the AI |
| AI inspection model | Finds defects on each side of the PCB |
| Mechanical holder | Flips the board, with no robot arm |
| OK and NG sorting | Sends good boards and defect boards to separate bins |
| Visual Editor | Lets operators teach the AI new defects |
How does the inspection run on a production line each day?
Each board enters the INDUSIA machine on a conveyor. The AI inspects side A, the holder flips the board, and the AI inspects side B in the same cycle. Then the board goes to the OK bin or the NG bin, so operators handle only boards that need a person's decision.
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The result does not depend on who is on shift or how long they have worked. The same model checks every board the same way, on both sides.
The machine runs on 2 production lines in Batam. Operators place boards and handle the NG bin. They do not need to tune the AI during normal work.
Running on two lines also shows the system works in daily production, not only in a demonstration. Both lines use the same approach, so lessons from one line carry over to the other.
What do PCI's operators do with the AI?
PCI's operators teach the AI in the INDUSIA Visual Editor. They mark good and defect areas on a PCB image, train the model, check the result, and send the model to the machine. No data scientist is needed, so the factory owns the way its AI learns.
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When a new kind of defect appears, an operator adds examples in the Visual Editor instead of filing a request. The model is trained, evaluated, and then promoted to the machine only after it is checked.
INDUSIA's team supports the first runs in the field, so operators are comfortable with the tool before they use it alone.
Because the Visual Editor works on images, an operator who knows what a good board looks like already has the skill that the tool needs.
How big is the deployment, and when will results be published?
INDUSIA's AI visual inspection runs on 2 production lines at PCI Elektronik in Batam, checking both PCB sides per cycle at ≥95% accuracy. Before and after results, such as time saved or defects caught, will be published here once they are measured. We do not publish numbers we have not measured.
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Scale is what we can state today: 2 lines, both PCB sides in every cycle, in a factory that is part of a global group.
If you run an SMT or PCBA line and want to see an AOI machine for PCB at work, the INDUSIA team can show the system and explain how it would fit your line. Start with the AI visual inspection page or contact us.
The system behind this case
ManufacturingAI AOI machine for PCB lines: both sides per cycle, 95%+ accuracy, running on 2 production lines. Includes an SMT false-call filter.Talk to us about your site
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