The Challenge

At one of the world’s leading steel plants, the Cut-to-Length (CTL) process was a critical stage in turning massive coils into perfectly measured steel sheets. Each coil, sometimes over 2 meters wide, was cut into sheets ranging from 800 mm to 2200 mm in width.

But there was a problem.

Despite their world-class operations, the company still relied on manual inspection to check for surface defects and used manual tape measurements to track sheet length. The process was:

• Slow – operators could only check a fraction of sheets at speed.
• Inconsistent – defect detection varied from person to person.
• Limited – no comprehensive records, just manual notes.

As the line speed pushed 55 meters per minute (MPM), human inspection was simply not enough. The company needed a solution that could see what the human eye could not, measure every sheet with absolute accuracy, and give them the visibility to continuously improve their CTL process.

The Vision

The client’s vision was bold:

• Automate defect detection across the entire surface of every sheet.
• Measure length and width precisely, in real time.
• Count plates per coil automatically without manual effort.
• Generate digital reports that could be traced back for quality, warranty, and audits.

This required a shift from manual inspection to an intelligent, camera-driven, AI-powered system—and Intelgic was brought in to make it happen.

The Intelgic Solution

Intelgic designed a turnkey automated inspection system tailored for the CTL line:

The Impact

The journey from manual to automated inspection empowered the steel company to:

• Build confidence in their product quality.
• Reduce waste and rework.
• Improve productivity on the shop floor.
• Provide digital quality records for customers, audits, and warranty validation.

This success story shows how Intelgic doesn’t just provide inspection tools—it builds intelligent systems that transform production lines, giving manufacturers the clarity and control they need for Zero Defect Manufacturing.