Written by Chris Jahn, ICS Consulting Supervisor, Houston
The Opportunity: Smarter Panel Builds Through AI
In the fast-evolving world of Operational Technology (OT) and Industrial Control Systems (ICS), precision and reliability are non-negotiable. Even the smallest oversight, like a missing component or incorrect part, can ripple through a project’s timeline and budget. At RED Group, where we specialize in delivering end-to-end OT and ICS solutions, we’re always exploring cutting-edge innovations to improve our project delivery lifecycle. One intriguing possibility is the application of Artificial Intelligence (AI) vision technology to improve panel and inventory verification processes.
Where Traditional QA Falls Short
Control panel assembly is a complex, detail-driven task. Ensuring every component is correctly installed and accounted for is essential, but manual verification is inherently prone to human error, especially across large-scale or high-volume projects.
Imagine these scenarios:
- A part is missing from a control panel build.
- An incorrect version of a component gets installed.
- Inventory shipments arrive incomplete or with mislabeled parts.
Even with experienced teams and rigorous checks, these errors can slip through, potentially causing costly rework or delays. While quality assurance procedures are in place, they aren’t foolproof, especially when deadlines tighten and pressure mounts.
How AI Vision Enhances Accuracy and Efficiency
Enter AI-powered vision systems.
AI vision technology paired with barcode/part number scanning can be a game changer for both panel verification and inventory validation. Using high-resolution cameras and machine learning algorithms trained on component datasets, AI can be used at key stages:
- Inventory Verification: As parts arrive for a panel build, AI can scan barcodes or part numbers to instantly verify that each component matches the bill of materials. Any discrepancies are flagged immediately, reducing the risk of incorrect or missing inventory going unnoticed.
- Panel Verification: Once a control panel is assembled, an AI vision engine can visually inspect the internal components to confirm correct placement, alignment, and presence, acting as a first or final verification step.
By integrating platforms like Teknoir, AI systems can be trained and fine-tuned for specific use cases and control panel standards. This approach augments human inspections, not replaces them, providing a reliable “second set of eyes” that never gets tired or overlooks a detail.
Advantages:
- Accuracy: AI doesn’t guess or assume; it validates exactly what it’s trained to recognize.
- Speed: Automated scanning dramatically shortens the time needed for inventory checks and inspections.
- Consistency: Unlike human inspectors, AI vision systems maintain the same level of scrutiny every time.
- Cost-Efficiency: Early detection of errors avoids expensive fixes down the line, contributing to project savings.
Disadvantages to Consider:
- Setup Time: Developing and training a custom AI vision engine tailored to specific panels or inventory can take time.
- Upfront Cost: There’s an initial investment in hardware, software, and training data, but it’s often offset by long-term ROI.
- Flexibility: Highly variable projects might require multiple AI models, increasing complexity.
What This Means for Your Next Project
While AI vision in control panel and inventory verification is still emerging, the benefits are already compelling. For asset owners and engineers focused on quality, speed, and efficiency, AI introduces a layer of precision that traditional processes can’t match.
At RED Group, we’re exploring partnerships and innovations, such as those through Teknoir, to integrate AI vision into our OT and ICS solutioning toolkit. The goal? Fewer errors, faster delivery, and greater peace of mind for our clients.
Curious about how AI can improve your control system projects?
Let’s talk. RED Group is committed to future-forward solutions that enhance every phase of your asset lifecycle. Contact us to learn more or schedule a consultation.
Chris Jahn, ICS Consulting Manager of RED Group’s Houston office, has over 12 years of experience in Industrial Control and Safety Systems in the Oil & Gas and Chemical industries. His expertise in PLC, HMI, Tool Automation, and Safety across multiple platforms makes him an invaluable asset to the RED Group Team.
