What Documentation Do I Need Before Installing Vision Systems?

A vision system installation goes better when the factory can explain the problem clearly.

Before installing computer vision, the most useful work is not buying the camera. It is preparing the information that helps the partner design the inspection correctly.

Good documentation prevents confusion. It helps define what the system should inspect, what counts as a defect, where the camera can be installed, how the line runs, what data must be stored, and what action should happen after detection.

Without this, implementation becomes trial-and-error on the production floor.

1. Inspection objective

Start with a short statement of the problem.

For example:

• Detect missing cap before packing
• Verify label presence and position
• Count pouches before carton filling
• Detect surface scratches after machining
• Confirm correct component orientation before assembly
• Read batch code before dispatch

The inspection objective should be specific. "Improve quality" is too broad. The camera needs a concrete decision to make.

2. Defect definition document

Create a defect definition document with images.

Include:

• Defect name
• Description
• Example images
• Acceptable examples
• Unacceptable examples
• Borderline examples
• Criticality level
• Action required

This document is essential. If production, quality, and the vendor do not agree on what a defect is, the system cannot be judged fairly.

3. Good and bad sample set

Prepare real samples. Do not rely only on drawings or verbal descriptions.

A useful sample set includes:

• Known good parts
• Known bad parts
• Borderline parts
• Different production batches
• Supplier variations
• Product variants
• Samples from normal handling
• Samples from actual defect history

The more representative the samples, the better the feasibility study and validation.

4. Line layout and installation constraints

Document the physical line.

Include:

• Conveyor or machine layout
• Available mounting points
• Working distance
• Line speed
• Product spacing
• Lighting conditions
• Power and network availability
• Dust, heat, oil, moisture, or vibration conditions
• Cleaning or washdown requirements
• Space for reject mechanism

A vision system is physical before it is digital. The camera must have a stable place to see the product properly.

5. Product and SKU details

If the line runs multiple products, document each SKU or product family.

Include:

• Dimensions
• Packaging variations
• Label variants
• Colour variants
• Batch code locations
• Count per pack
• Changeover process
• Inspection recipe needs

This prevents the system from being designed only for one ideal product while the factory actually runs many variants.

6. Production process information

The vision partner should understand how the line operates.

Useful details include:

• Shift pattern
• Production volume
• Normal stoppages
• Changeover frequency
• Manual inspection points
• Current rejection process
• Rework process
• Downstream impact of missed defects
• Existing quality checks

This helps design a system that fits the production rhythm.

7. Integration requirements

Decide what systems the vision system must talk to.

Document:

• ERP, MES, or production software
• PLC or machine signals
• Dashboard requirements
• Accepted/rejected count flow
• Batch or work order reference
• User roles
• API availability
• Network/security rules
• Data export needs

AICAN Optiwise can help manufacturers connect inspection results with production, inventory, quality, and dispatch workflows. Integration should be planned before installation, not patched later.

8. Action workflow after detection

Write what happens when the system detects a defect.

Define:

• Does the line stop?
• Is the item automatically rejected?
• Does an operator remove it?
• Who reviews uncertain cases?
• Can operators override?
• How are overrides logged?
• What threshold triggers escalation?
• Who owns repeated defects?

Detection without action creates noise. Workflow documentation turns detection into improvement.

9. Acceptance criteria

Before go-live, define acceptance criteria.

This may include:

• Detection performance on sample set
• False reject limit
• False accept expectation
• Line speed capability
• Operator usability
• Integration success
• Evidence storage
• Reject mechanism timing
• Reporting output
• Sign-off process

Acceptance criteria keep the project objective. They prevent endless subjective debate.

10. Maintenance and support plan

Document who owns routine checks and support.

Include:

• Daily operator checks
• Weekly maintenance checks
• Lens cleaning method
• Lighting inspection
• Recipe change process
• Support escalation
• Spare parts plan
• Software update process

Maintenance documentation protects reliability after go-live.

Where AICAN fits

AICAN believes manufacturing digitization works best when technology is connected to real operating discipline. Documentation may feel slow at the beginning, but it saves time during installation, training, support, and scaling.

AICAN Optiwise can help connect inspection documentation, production context, and quality actions into a practical workflow. You can learn more at About AICAN.

Founder's Note

Good documentation is not paperwork for paperwork's sake. It is how a factory transfers its practical knowledge into a system that must make consistent decisions.

If the factory cannot define the defect clearly, the camera cannot solve it cleanly.

FAQs

1. Do we need sample images before installation?

Yes. Real good, bad, and borderline samples help validate whether the system can detect the required condition.

2. Who should prepare defect definitions?

Quality should lead, with input from production, customer requirements, and the implementation partner.

3. Is line layout documentation important?

Yes. Camera mounting, working distance, lighting, vibration, space, and rejection mechanism design depend on physical layout.

4. Should integration requirements be documented early?

Yes. Data flow, ERP/MES connection, dashboard needs, and security rules should be known before deployment.

5. What is the most important document?

The defect definition document with real images is usually the most important because it defines what the system must decide.