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Brocode SolutionsAI Software Development

Industrial QA, edge AI

Detect what your rule-based vision can't.

Subtle surface defects, new SKU variants, contamination - on a 24V edge appliance that talks to your PLC over PROFINET. Deployed in 60 days, with a documented detection-rate benchmark on your rejected-units library before contract signature.

98.2%

Basler ace2

JETSON AGX ORIN

YOLOv9 + SAM2 + EfficientAD

320 ppm | 17.8 ms

[14:22:08.412] REJECT - PLC #4, slot 12, class: surface_scratch_0.4mm

A 0.4 mm surface scratch caught on a sheet-metal stamping line. The same loop runs on retail Re-ID and perimeter ANPR scenes.

  • +12.4 pp

    Defect-detection delta vs rule-based vision on subtle surfaces

  • 99.1%

    Detection rate on UAE packaging-plant historical reject library

  • <22 ms

    Inference latency at 320 ppm on Jetson AGX Orin

  • 0.74%

    Shrink rate after deployment - regional retailer, 84 stores

Where rule-based vision breaks

Three real failure modes that drive the customer-rejection P&L line.

Each one has a before-and-after image in the lead-magnet benchmark, drawn from anonymised UAE and KSA plant data.

Subtle surface defects

A 0.4 mm scratch on brushed aluminium with directional light is invisible to a thresholded edge detector. A deep model trained on your reject corpus catches it. The benchmark shows +12.4 pp on subtle-surface classes.

Novel SKU variants

A new pack format introduces lighting, shape, and label changes the rule-based recipe was never tuned for. The Inspector Loop adds the new SKU from operator-labelled samples in days, not weeks.

Lighting drift over a shift

A panel-mounted vision rig calibrated to morning ambient becomes a false-positive generator by 16:00. The bespoke model we build for you is robust to seasonal and shift-time lighting variation by design - the corpus is balanced for it.

The Brocode detection stack

From camera frame to PLC reject event - the latency budget, layer by layer.

Measured on your hardware during commissioning. Acceptance test pack includes the realised latency by layer.

  1. Camera

    Industrial machine-vision camera

    Basler ace2, IDS, or Hikrobot at 1280x720 to 4K at 60-150 fps depending on line takt. GenICam over GigE Vision; PoE+ where applicable. Lighting and lens calculated against the defect class set.

    ~3 ms shutter to frame buffer

  2. Edge

    NVIDIA Jetson AGX Orin 64GB

    In a fan-less IP54 enclosure, mounted in the line panel. For higher-throughput lines, an NVIDIA IGX Orin appliance. PROFINET / EtherNet/IP / Modbus TCP interfaces; PTP time sync with the PLC.

    <8 ms model dispatch

  3. Model

    YOLOv9-c + SAM2 + EfficientAD, TensorRT distilled

    YOLOv9-c for primary defect classification, SAM2 for pixel-accurate contour, EfficientAD for unsupervised anomaly on rare classes. All three distilled into a single TensorRT-optimised model.

    <22 ms inference at 320 ppm

  4. PLC

    Reject event to Siemens / Rockwell / Beckhoff

    REJECT_BIT and slot index written to a tagged PLC variable; the rejector arm fires before the part leaves the inspection window. Defect event also written to SAP S/4HANA QM or Oracle EBS Quality via the OPC UA bridge.

    <7 ms PLC write

  5. Loop

    Inspector Loop annotation tool

    Quality engineer reviews a sample of rejections; mislabelled cases feed the retraining DAG. A new model version is staged, canary-tested on a shadow camera, and promoted when the defect class beats the previous version.

    New defect class without a change order

Benchmark vs the alternatives

Cognex VisionPro, Keyence CV-X, AWS Lookout for Vision, or DIY - the honest read.

The full 14,000-image benchmark across six defect categories is the lead magnet below.

CapabilityBrocodeCognex VisionProKeyence CV-XAWS Lookout for VisionIn-house DIY
Subtle surface-defect detection rate

See benchmark below.

+12.4 pp on benchmark vs best alternativeRule-based, plateaus on subtle defectsRule-based, similar plateauLimited to taught defect classesVariable, build-dependent
New defect class without integrator visitInspector Loop - operator-labelledVendor visit + change orderVendor visit + change orderCloud-side annotation, latency hitDIY pipeline you build
Sub-40 ms latency at 320 ppm<22 ms on Jetson AGX Orin~30 ms typical~25-35 ms typicalCloud round-trip - rarely meets taktDepends on the build
On-premise / edge deploymentCloud-only - no edge mode
PROFINET / EtherNet/IP / Modbus to PLCSiemens, Rockwell, Beckhoff supportedYou wire it
IP54 fan-less enclosureDefault, IEC 62443 awarenessN/A - cloudSource and certify yourself
Co-exists with existing vision rigReads Cognex / Keyence output, adds learned layerCloud onlyVariable
Pre-contract benchmark on 2K of your reject imagesFree, under NDA, within 10 business daysPoC charged
Egress / per-image cost on continuous videoNone - edge inferenceNoneNonePer-image egress + inferenceNone

What plant directors push back on

Three objections, three honest answers from the vision lead.

Objection 01

Our line runs at 320 parts per minute - your model needs to make a decision in under 40 ms. Can it actually do that on an edge box?

Yes, and we will prove it on your line. The TensorRT-distilled model dispatches in under 22 ms on Jetson AGX Orin 64GB at 4K input, leaving margin to write the reject event to the PLC inside the line's takt. Higher throughputs (>400 ppm) move to NVIDIA IGX Orin or a multi-Jetson load-balancer. We publish the latency budget by layer and we measure it on your hardware during commissioning.

Proof: anonymised UAE packaging-plant reference - 12 defect classes, 99.1% detection rate on the historical reject library, <22 ms inference latency at 320 ppm sustained.

Objection 02

Every time we add a new SKU, the Cognex integrator wants three days and a change order. How does your system retrain, and who pays for it?

New SKU and new defect classes are added through the Inspector Loop annotation tool, operated by your quality engineer - not an integrator visit. A new version is trained on the operator-labelled samples, canary-validated on a shadow camera, and promoted when the validation set is beaten. Retraining is part of the run-phase SLA; no change order needed unless the line geometry physically changes.

Proof: anonymised KSA pharma blister-pack reference - contamination detection lifted from 91.2% to 99.7%, with three new pack variants added by the in-house quality team in the first six months. No integrator visit required.

Objection 03

We have already paid for Cognex and Keyence sensors. You can't expect us to rip them out. How do you co-exist with the rig we own?

We do not rip anything out. The appliance we install for you reads the existing Cognex or Keyence pass/fail signal, adds a learned layer on top, and writes its own reject event downstream. The two systems run in parallel during commissioning; you see the per-defect-class delta on the same dashboard before flipping the rejector authority. If the Brocode layer underperforms, the rejector authority stays with the rule-based rig.

Proof: anonymised regional retail reference - shrink reduction from 1.6% to 0.74% across 84 stores in 11 months, running alongside the existing Tyco Sensormatic EAS without modification.

Edge appliance & integration

The hardware spec sheet, the protocols, and the systems we write into.

Appliance

Jetson AGX Orin 64GB - IP54 fan-less enclosure

For higher-throughput lines, NVIDIA IGX Orin. Power draw 30-60 W. MTBF >100k hours. PoE+ for the camera, 24 VDC for the appliance, dual-NIC for line and OT.

  • - IEC 62443 awareness statement
  • - IP54 default; IP65 / ATEX on request
  • - Customer-managed keys on every artefact

PLC integration

PROFINET, EtherNet/IP, Modbus TCP

Siemens S7, Allen-Bradley ControlLogix, Beckhoff TwinCAT. PTP time sync.

MES / SCADA

OPC UA

To AVEVA, Siemens MindSphere, Honeywell Forge. Quality events to SAP S/4HANA QM and Oracle EBS Quality.

Retail loss-prevention

Re-ID on AXIS / Hanwha

Fine-tuned OSNet backbone; ties into Tyco Sensormatic EAS and Genetec Security Center event streams.

Facility security

ANPR on Hailo-8

Pole-mounted enclosures, integrated with MoI vehicle databases via TDRA-approved sovereign brokers.

Inspector Loop

Operator-labelled retraining

New SKU or defect class added without an integrator visit. Canary on a shadow camera before promotion.

Conveyor camera capturing a stamped sheet metal part with overlaid bounding box and PLC reject event

Case studies

Four references, one phone call away.

  • UAE packaging plant

    12 defect classes, 99.1% detection rate on the historical reject library, <22 ms latency at 320 ppm. Customer rejections fell 86% inside six months.

  • KSA pharma blister-pack

    Contamination detection lifted from 91.2% to 99.7%. FDA-grade audit log. Three new pack variants added by the in-house quality team in six months.

  • Regional retail loss-prevention

    Shrink reduction from 1.6% to 0.74% across 84 stores in 11 months. Re-ID on AXIS cameras alongside the existing EAS estate.

  • UAE federal facility ANPR

    98.7% plate read accuracy in mixed Arabic-English-Latin scripts. Hailo-8 pole-mounted, TDRA-approved sovereign broker for vehicle database lookups.

Free download

The Industrial Vision Benchmark - Cognex vs Keyence vs AWS vs YOLOv9

A 28-page PDF and an interactive defect-class explorer. 14,000 images, 6 defect categories, full per-class detection rate, inference latency, and false-positive comparison.

  • Benchmark setup and protocol
  • mAP, recall, false-positive comparison per class
  • Edge inference latency on Jetson AGX Orin
  • PROFINET and OPC UA integration patterns
  • <60-day deployment evidence
  • Pre-contract free benchmark offer on 2,000 of your reject images

Instant download. No spam. Unsubscribe any time.

Questions from plant and quality leads

Frequently asked.

Every answer below comes from a real SOW we have signed on a UAE or KSA plant floor.

Ask a different question
  • Yes, and we will prove it on your line. The TensorRT-distilled model dispatches in under 22 ms on Jetson AGX Orin 64GB at 4K input, leaving margin to write the reject event to the PLC inside the line's takt. Higher throughputs (>400 ppm) move to NVIDIA IGX Orin or a multi-Jetson load-balancer. We publish the latency budget by layer and we measure it on your hardware during commissioning. Proof: anonymised UAE packaging-plant reference - 12 defect classes, 99.1% detection rate on the historical reject library, <22 ms inference latency at 320 ppm sustained.

Pre-contract benchmark

Send 2,000 reject images. Receive a benchmark in 10 business days.

No SOW required. Sign an NDA, send the reject corpus, receive a per-defect-class detection-rate report. If the delta is not worth the project, you keep the report.

Direct WhatsApp: +971 50 761 2213

Email: hello@brocode.ae

HQ: Al Maryah Island, ADGM, Abu Dhabi

Dummy line demo: bookable at our Abu Dhabi office

Quote request

Send us 2,000 of your reject images - we come back with a detection-rate benchmark

A senior vision engineer reviews your sample, runs the Brocode stack against it, and shares the per-defect-class benchmark within 10 business days. Under NDA.

Prefer chat? Message us on WhatsApp — we'll see it within working hours.

Send reject imagesWhatsApp