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Industry
Automotive
Challenge
Intermittent failures in assembled boards
Solution
Cybord ShieldScan
The Customer
A Tier 1 automotive electronics manufacturer responsible for high-reliability board assemblies used in next-generation vehicles.
The Challenge
The manufacturer began seeing intermittent failures in assembled boards — short circuits caused by tiny components dislodging during production. The failures were hard to detect and even harder to trace. The issue didn’t appear in every board, nor did it involve the same component or location each time. In some cases, the components were as small as 0.5mm, making manual inspection impractical.
The company needed a faster, more accurate way to pinpoint misplaced components, down to their exact location on the board.
The Solution: Cybord ShieldScan
The manufacturer turned to Cybord ShieldScan, a visual-AI PCBA inspection solution that integrates directly with existing AOI systems.
ShieldScan uses high-resolution imaging and visual AI to detect anomalies in real time, capturing the precise X/Y coordinates and reference designator (ref-des) of every component on every board. Unlike traditional inspection methods that rely on sampling or surface-level checks, ShieldScan sees at the component level — identifying misalignments, missing parts, and micro-shifts that may go unnoticed until the product fails.
Results:
With ShieldScan in place, the manufacturer was able to:
- Identify boards with misplaced components before they leave the SMT line
- Identify the misplaced components with sub-millimeter accuracy
- Resolve board-level quality issues rapidly
- Avoid performance failures and reduce rework cycles
- Strengthen overall production reliability without disrupting existing workflows
The solution runs in real-time, overlaying a layer of intelligent visual-AI inspection on top of the manufacturer’s existing AOI systems – improving detection without replacing existing equipment.
Customer Quote
Cybord ShieldScan is a great inline solution that enhances our AOI equipment with a powerful visual AI layer. Fast, accurate, and efficient — exactly what we needed to solve a high-impact problem.
Dir. Of Operations, Tier 1 Automotive Manufacturer.
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