AI-Powered Visual Inspection in Canadian Heavy Industry | Part 2

Hello Industrial Clients, Engineers, and QA/QC Leaders,

In Part 1 of our series, we explored how AI-powered visual inspection is reshaping quality assurance in Canada’s heavy industrial sector. We discussed how computer vision models, trained on CSA, ASME, and API standards, are being used to automate weld assessments, reduce manual fatigue, and enhance compliance across structural steel, piping, pressure vessels, and tank projects.

Now in Part 2, we shift from theory to practice—with a real-world implementation that demonstrates how this AI technology performs in the field and the impact it delivers when deployed at scale.

A Real-World Application of AI in Weld Inspection

A leading global oil and gas fabrication company recently integrated AI-powered visual inspection systems across multiple fabrication yards to enhance their weld quality assurance processes.

These AI systems are designed specifically for visual inspection, not as a replacement for NDT, but as a first-pass, high-speed screening solution to identify common weld surface defects such as:

• Cracks

• Porosity

• Undercuts

• Weld misalignment

Instead of relying solely on manual inspection, which is often time-consuming, inconsistent, and prone to human fatigue, the company leveraged high-resolution imaging paired with deep learning algorithms to detect visual defects in real time—as the welding was being completed.

Inline Deployment with Immediate Benefits

Deployed directly on the production line, these AI systems were configured to continuously monitor and analyze welds on pressure-containing components and structural modules.

Here’s what made this deployment stand out:

• Speed: Inspections were conducted 8x faster than traditional methods.

• Accuracy: The AI solution reduced false positives by over 60%, leading to fewer unnecessary holds and manual rechecks.

• Focus: Certified inspectors could redirect their time from routine scanning to validating actual defects, making the review process smarter and more focused.

Measurable Outcomes After 12 Months

The implementation of AI-powered visual inspection brought measurable improvements in both efficiency and quality control:

🔧 30% reduction in weld-related rework, primarily driven by earlier detection and immediate correction of defects.
📏 Improved compliance with ASME Section VIII and API 650 standards—validated during internal audits and third-party inspections.
⏱️ Inspection cycle time reduced by 75%, from 20 minutes per weld to less than 5 minutes, dramatically improving project throughput.
🧾 Full digital traceability with weld image logs and AI-generated classification data, enhancing auditability and repair history tracking.

Why It Matters for Heavy Industry

In high-stakes fabrication projects—whether for energy, shipbuilding, or industrial infrastructure—QA/QC must be fast, consistent, and auditable.

This case study proves that AI isn’t just hype. It’s a practical, production-ready tool that can:

• Eliminate bottlenecks in inspection workflows

• Lower the cost of quality through reduced rework

• Ensure compliance with stringent codes

• Support inspectors without replacing their expertise

Ready to Explore What AI Can Do for Your QA/QC?

This isn’t just innovation—it’s transformation.

If you’re considering automation to scale your inspection process, reduce rework, and improve confidence in your weld quality—now is the time to explore AI.

📩 Contact Engrity today to book a consultation with one of our AI experts and see how visual inspection tools can fit into your current QA/QC strategy—whether you’re fabricating, assembling, or operating in the field.

Let’s elevate your AI adaptation journey—together