Modern manufacturing demands absolute accuracy, especially as products become more complex and customer expectations continue to rise. Mistakes in assembly, material usage, sequence of operations, or part placement can lead to:
- Defective products
- High rework costs
- Production delays
- Warranty issues
- Customer complaints
- Compliance failures
Traditional process monitoring relies on manual supervision, which is slow, inconsistent, and prone to error—especially in high-speed, multi-step processes.
To solve this, manufacturers are now adopting camera-based AI systems, such as Intelgic’s Process Monitoring AI, that closely observe every step of the Standard Operating Procedure (SOP) and compare it with authoritative datasets like the MES, Bill of Materials (BOM), product specifications, and other digital sources of truth.
This ensures error-free production, consistent quality, and full traceability from start to shipment.
What Is AI-Driven Manufacturing Process Monitoring?
Manufacturing process monitoring refers to the real-time observation and verification of:
- Each step of the assembly process
- Parts and materials used
- Operator actions
- Sequence of operations
- Tool usage
- Component orientation and placement
- Process compliance with SOPs
Using industrial cameras and Intelgic’s AI, the system watches the process like a highly skilled inspector—only faster, more accurate, and 100% consistent.
The AI validates that each step is performed correctly against known standards, such as:
This creates a closed-loop quality control ensuring correctness at every stage.
Why SOP and MES/BOM Validation Is Essential
In many industries, errors happen because:
- Operators skip assembly steps
- Parts are installed in the wrong sequence
- Wrong materials or quantities are used
- Orientation of parts is incorrect
- Tools are not used properly
- Documentation/SOP is not followed
- Mixing of batches or variants
Even small errors can lead to catastrophic failures in industries like automotive, medical devices, electronics, aerospace, and heavy engineering.
By comparing what the camera sees with what the MES/BOM expects, the AI ensures:
- Every step is completed
- The right part is used
- Nothing is missing
- Nothing extra is added
- The assembly matches the digital blueprint
- Variation between operators no longer affects quality
This eliminates the risk of human oversight.
How Intelgic’s AI-Based SOP Monitoring System Works
Camera-Based Observation
Multiple industrial cameras are installed:
- Over the workstations
- Above conveyors
- On robotic cells
- At inspection points
These cameras continuously capture:
- Operator actions
- Part placements
- Assembly sequences
- Component presence/absence
- Tool usage
- Material movement
AI Understanding of Actions
AI uses computer vision models trained to identify:
- Parts (small, large, complex)
- Orientation of components
- Tools and their movement
- Sequence of assembly steps
- Fasteners, clips, screws
- Operator hand movements
- Completion of each stage
The system understands what the operator is doing and compares it with what should be done.
SOP Validation
The AI checks each action against:
- Digital SOP steps
- MES instructions
- Product variant requirements
- Work order configuration
For example, if Step 3 requires attaching two screws, the AI ensures:
- Exactly two screws are placed
- Correct type of screws
- Correct hole positions
- Correct orientation
- No cross-threading or missing screw
If anything is incorrect, the system raises an alert.
MES/BOM Data Cross-Verification
The AI ensures that the parts used match the digital BOM:
- Right part number
- Right material
- Right quantity
- Correct variant
- No wrong or additional part
For example:
- BOM requires Part A → AI checks if operator picked Part A, not Part B
- BOM requires 3 clips → AI verifies 3 clips are used
- MES recipe requires left-handed assembly → AI ensures matching orientation
This prevents assembly errors and mixed-model mistakes.
Real-Time Alerts & Error Prevention
Whenever the AI detects:
- Wrong part
- Missing step
- Incorrect sequence
- Wrong orientation
- Extra or fewer materials
- Skipped SOP step
- Misassembly
...it instantly alerts the operator or stops the line.
Visual overlays show exactly what went wrong, allowing immediate correction.
Data Logging & Traceability
All actions are recorded:
- Time-stamped
- Step-wise compliance
- Images/videos of assembly
- Pass/fail records
- Batch information
- Operator performance metrics
This creates a full Digital Quality Certificate (DQC) for each product.
Use Cases Across Industries
Automotive Manufacturing
- Dashboard assemblies
- Wiring harness verification
- Engine and suspension assemblies
- Fastener detection
- Accessory placement validation
Medical Device Manufacturing
- Syringes, catheters, valves
- Stents, implants
- Assembly step compliance
- Material traceability
Electronics Manufacturing
- PCB assembly step verification
- Connector orientation
- Component presence/absence
- Final assembly checks
FMCG, Packaging & Consumer Products
- Correct packaging materials
- Label and seal verification
- Accessory or part presence check
Industrial Equipment Production
- Kits/assembly BOM validation
- Mounting and fastener validation
- Tool and part verification
Key Features of Our AI Process Monitoring System
Benefits of AI-Powered SOP Monitoring
1. Zero-Error Production
AI eliminates mistakes that humans often overlook.
2. Fully Compliant Production
Automatic enforcement of the correct process and BOM.
3. Standardized Operations
No variation between different operators or shifts.
4. Preventive Error Control
Errors are detected before they happen, not after completion.
5. Time & Cost Savings
Less rework, scrap, manual inspection, and warranty claims.
6. Traceable Production
Every product gets a digital record of assembly correctness.
7. Better Productivity
Operators focus on work—AI handles verification.
The Future of Manufacturing: Autonomous Quality Assurance
AI-driven process monitoring is the next stage in the Industry 4.0 journey:
Manufacturers who adopt camera-based AI monitoring now will be future-proof—ready for the age of autonomous, self-correcting production systems.
Manufacturing today requires error-free, traceable, and repeatable production processes. Our camera-based AI monitoring system bridges the gap between physical operations and digital manufacturing data (MES/BOM/SOP), ensuring that every product is assembled exactly as intended.
By validating each step using cameras, AI, and data-driven comparison, we empower manufacturers to achieve:
- Zero-defect manufacturing
- Complete SOP compliance
- Real-time error prevention
- Reduced rework and cost
- Faster, more reliable production
- Superior customer satisfaction
This is the future of smart manufacturing—AI watching every step, ensuring every product is built right, the first time.
