Sensors International 3 (2022) 100132

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Exploring impact and features of machine vision for progressive industry

4.0 culture
Mohd Javaid a, *, Abid Haleem a, Ravi Pratap Singh b, Shanay Rab a, Rajiv Suman c
a
Department of Mechanical Engineering, Jamia Millia Islamia, New Delhi, India
b
Department of Industrial and Production Engineering, Dr B R Ambedkar National Institute of Technology, Jalandhar, Punjab, India
c
Department of Industrial & Production Engineering, G.B. Pant University of Agriculture & Technology, Pantnagar, Uttarakhand, India

A R T I C L E I N F O A B S T R A C T

Keywords: Machine Vision (MV), like other digital technologies, is a critical component of Industry 4.0. The high volume of
Machine vision data accessible by visual equipment can well quickly detect & flag faulty goods while recognising their defects,
Industry 4.0 thereby allowing rapid and efficient intervention in industry 4.0. The versions of MV are essential for efficient
Computer vision
production on a scale with applications in quality assurance, enforcement, and inventory management. The
Imaging
Inspection
removal of human error simultaneously minimises the probability of a mistake. This paper briefly discusses MV
and how it helps Industry 4.0. Various collaborative features and smart technologies of MV for Industry 4.0 are
diagrammatically presented. Further, the authors have identified and discussed twenty significant applications of
MV for Industry 4.0. In Industry 4.0 and associated digital industry transition, every step in the process, including
manufacturing, inventory control of the supply chain, and more, involves a different and innovative approach.
One of the aims is to develop MV capable of seeing, communicating, and working with more accuracy better than
human beings. Enabling robots to perceive and help people in dynamic systems provides the way for many op-
portunities. In the smart plant of the future, MV plays a significant role, in which automated production lines will
adapt themselves to optimise productivity, performance, and profitability.

1. Introduction
Today, Industry 4.0 is one of the most debated subjects in the
manufacturing world. Industry 4.0 refers to several new technologies that
can revolutionise manufacturing. These advanced technologies are ro-
botics, artificial intelligence, machine vision, big data, cloud computing,
and machinery education. This fourth industrial revolution has an
enormous capacity for enhancing sustainability, reducing pollution,
improving the efficiency of the products, increasing production stability,
reducing running costs, and providing the plant with various other
benefits. Industry 4.0 creates a 'smart plant,' which uses data from the
different sensors to improve processes. Machine vision (MV) belongs to a
dynamic smart production strategy, allowing computers and machinery
to 'see' the world through the extraction, processing, and analysis of vi-
sual knowledge [1–3].
MV system facilitates automated inspection and review of systems by
image processing, including automatic inspection, monitoring of pro-
cesses, and robotic guidance. MV is a computational capacity applied in
new ways for current technology to resolve real problems. MV is a field of
systems engineering that can be seen as different from computational
vision. It is the system body, and computer vision is the system intellect,
like computer frameworks for what is inside, likes device chips powering
the computer. MV has now automated the log rotation operation, readily
applicable for the industry [4,5]. The scanned information with the help
of this technology is analysed to maximise the performance, which is
historically based exclusively on human evaluation. The application of

* Corresponding author.
E-mail addresses: mjavaid@jmi.ac.in (M. Javaid), ahaleem@jmi.ac.in (A. Haleem), singhrp@nitj.ac.in (R.P. Singh), shanayrab753@gmail.com (S. Rab), raje.
suman@gmail.com (R. Suman).

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https://doi.org/10.1016/j.sintl.2021.100132
Received 29 August 2021; Received in revised form 30 October 2021; Accepted 30 October 2021
Available online 6 November 2021
2666-3511/© 2021 The Authors. Publishing services by Elsevier B.V. on behalf of KeAi Communications Co. Ltd. This is an open access article under the CC BY license
(http://creativecommons.org/licenses/by/4.0/).
M. Javaid et al.
high-speed vision technologies automatically detects off-size plates,
maintaining consistent production and eliminating additional material
waste. The machine vision allows a company to reap the durable benefits
of increased manufacturing accuracy [6–8].
MVs techniques are interdisciplinary as it uses cameras, sensors and
computing power to interpret pictures and enable machines to complete
industrial tasks, such as production and verification of quality. For In-
dustry 4.0, MV is an essential component that supports industrial auto-
mation technologies in several respects, such as performance
improvement through stock improvement and defective component
detection and product quality improvement. This is helpful for imaging
automated inspection and analysis for such applications as automated
inspection, process control, and robot guidance. This technology is
beneficial to reduce labour costs [9,10]. In addition to decreased labour
costs, errors or deviations from expectations are made less space, which
improves overall product consistency and reduces waste. The actual uses
are almost unlimited in production, which can maximise operations, ef-
ficiency, and revenues.
A computer viewing system includes applications for viewing the data
and seeing what the cameras are ‘searching for’ to analyse, maintain and
program the hardware. Different software is available to balance the MVs
framework. Machine learning will teach technology to identify various
borders used to sort the objects in the process line. The device will spot,
fit and count patterns on the process line employing pattern recognition.
Different patterns or more complicated patterns may be taught to the
computer through a simulator through profound experience. It helps
them to understand an object more correctly, put an item more accu-
rately and perform complicated activities such as inspections more
quickly [11–13].
MVs are used for automated machine control in the manufacturing
industries. It requires computer vision for processing and understanding
images. Computer vision operates on the algorithms which recognise the
visual flaw and comprise the whole system to eliminate defects. The
image can be easily captured by optical sensors, digital cameras, and
ultraviolet cameras. The hardware captures the picture and makes it
visible. The hardware can analyse digital data via image processing al-
gorithms. The computer is directed to take the appropriate action based
on knowledge obtained in the previous process [14,15]. This paper
provides an overview of MV in the context of Industry 4.0.
2. Research objectives
Industry 4.0 technologies aim to improve manufacturing processes
through computer technology which helps to improve automation and
productivity. MV technology also allows factories to function quicker and
better in the manufacturing process and increase the demand for vision
systems for machines. It allows for a higher automation rate and enhanced
vision systems, which enable the robots to occupy a more significant part
of the industrial job. Predictive maintenance systems may be triggered by
visual evidence. These systems rely more on sensors like heat and vibra-
tion detectors. Software for image processing is running on hardware that
determines image processing speed [16–18]. The required rate depends
on the application case and minimising hardware costs at the correct
speed. The primary research objectives of this article are as under:
RO1: - To brief about Machine Vision and its working steps;
RO2: - to discuss how Machine Vision helps Industry 4.0;
RO3: - to discuss collaborative features and smart technologies for
practising Machine Vision in Industry 4.0;
RO4: - to identify and discuss significant applications of Machine
Vision in Industry 4.0 culture;
3. What is machine vision?
Machine vision is a term used in industry to describe the technology
and methodologies utilised to deliver imaging-based autonomous in-
spection and analysis for applications. MV is used in the industry for
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material inspection, object recognition, pattern recognition, electronic
component analysis, signature recognition, optical character recognition,
and money recognition. It aims to find new ways to combine existing
technology and apply them to real-world problems [19,20]. The term is
most typically associated with these skills in industrial automation,
although it is also used in other contexts such as security and vehicle
navigation. The MV process begins with a detailed analysis of the needs
and project, developing a solution. The procedure starts with imaging
and then automatic picture analysis and information extraction [21,22].
Fig. 1 shows the steps of the MV process system.
Any case of any visual system's sensitivity and resolution are two
critical criteria. The ability of a machine to see in dim light or detect weak
impulses at infrared wavelengths is referred to as sensitivity. A machine's
resolution refers to its capacity to discriminate between objects. In gen-
eral, the smaller the field of vision becomes as the resolution increases.
The terms sensitivity and resolution are interchangeable. Raising sensi-
tivity lowers resolution, while increasing resolution raises sensitivity,
assuming all other factors remain constant [23,24].
Although different forms of computer vision have been used for many
decades, recent machine learning and image processing developments
have enabled new production cases. AI-supported computer vision sys-
tems can operate in increasingly diverse contexts, no longer restricted to
organised and routine activities. This works continuously with operators
to improve efficiency, decrease mistakes and improve data. When
dynamically embedded in the intelligent plant, computer vision systems
enhance visual and human output online. The continuous insight of real-
time into processes is one of the claims of computer vision. In the context
of data from computers and other, non-visual operator data obtained by a
computer vision system becomes more important. MV sends signals to
respond to the behaviour of an operator and affects them in real-time. It is
a crucial part of the modern factory in its present condition [25–27].
MV defines many techniques for obtaining visual data from hardware
and processing and analysing information in its most broad terms.
Modern computer vision solutions are versatile, unlike existing systems.
These modern technologies have enhanced their ability to perform in half
and unstructured scenarios rather than handling structured information
in managed settings. In Industry 4.0, MV technologies can work with and
respond to operators and allow for new ways of contact between digital
and human beings [28,29].
MV use of evolving technology such as AI and deep learning, along
with advanced data analytics, is bringing about a short revolution. MV
systems become quickly to meet and often even exceed market specifi-
cations. The systems are matching ever-increasing rates of demand
quicker and more affordable at the same time. MV play options are much
more intuitive and simpler to use [30,31]. It gains information to cope
with manufacturing cycles and other process variations across new
technologies. In the assembly line, the advantages of sophisticated MV
are enormous. Modern computer vision can accelerate processes of pro-
duction and inspection to frame rates. Robots may depend on explicit
imagery to distinguish the sharpest differences in picking and sorting
components [32,33].
4. How machine vision helps industry 4.0?
Industrial revolutions have shaped the society we live in and the way
we make items throughout history. Water and steam-powered machines
were introduced during the 1st industrial revolution, allowing for the
widespread production of commodities. The 2nd revolution was distin-
guished by the use of electricity to power production lines and increase
operating hours. The 3rd industrial revolution saw the development of
electronics, computers, and Programmable Logic Controllers (PLCs),
which led to the automation of production lines and processes. Cyber-
physical systems enhance factory automation with better data and ma-
chine learning in the 4th industrial revolution, known as Industry 4.0
[34–36]. Fig. 2 shows some of the major components of Industry 4.0 in
developing a Smart factory.
M. Javaid et al.
Fig. 1. Working steps of machine vision system.
Fig. 2. Industry 4.0 Smart factory components.
MV technology is critical in collecting the physical world and trans-
ferring it into networked, digital data, as Industry 4.0 predicts a higher
dependence on machine learning. This data may be evaluated and pro-
cessed in real-time to raise operational efficiency, maintain quality
standards, and reduce waste, allowing firms to improve productivity,
maintain quality standards, and reduce waste in a continuous develop-
ment cycle. In fact, after investing in smart factory projects, organisations
report increases of up to 12% in areas like manufacturing production,
factory utilisation, and labour productivity [37,38].
Machines are connected in Industry 4.0 to establish an ecosystem
known as the Internet of Things (IoT). The integration of MV with
automation systems improves the quality and amount of data collected,
allowing the smart factory to become a reality. This extra information is
used in applications to ensure quality, reduce waste, and improve safety
while increasing production speed. MV is a developing market expected
to grow in the long run and has a promising future because of its ease of
use, and new non-industrial uses are emerging. Industries that have
already adopted MV are reaping the benefits of increased profit margins,
while non-adopter competitors are lagging [39–41].
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MV also complements IoT automation technology. Robotics inspec-
tion stations can operate faster than employees and automatically, as
faults and exceptions are easily identified. Management structures con-
structed with MV show greater mobility and travel capability for robots
and cobots and assist them at working with human staff more quickly and
efficiently. MV allows robotics in warehouses and other settings with a
high probability of error to increase response time and limit defects
which lead to a company loss [42,43].
A significant time for technical progress is the explosion of the In-
dustrial Internet of Things (IIoT). The IIoT offers companies an extraor-
dinary view from top to bottom of their activities. Cloud-based sensors
and hubs for resource planning provide two-way data mobility from local
and remote assets to business partners. MV increases the power and us-
ability of sensors around the IoT [44,45]. The sensors have a degree of
analysis and abstraction that can be used in decision-making or further
automation rather than supplying brute data. MV can help minimise
broad-scale IoT accumulation needs for bandwidth. Usually, machine
view testing is performed at the data source, compared with collecting
photographs and data and sending them to analytical Servers [46,47].
M. Javaid et al.
5. Collaborative Features of Machine Vision for industry 4.0
Literature reports classical features of MV and investigations for its
application in the environment of Industry 4.0. Fig. 3 explores those
appreciable and fundamental features of the MV concept graphically. The
features like barcoding reading, detection of defects, traceability, soring
process, optical verification, vision robotics, etc., further made the ap-
plications of MV in Industry 4.0 more decent and adequate. As mentioned
earlier, the overall impact of the features is to improve the practice of the
MV culture in the Industry 4.0 scenario [48–50].
Industrial revolutions have transformed the world where manufac-
turers can produce products throughout human history [51,52]. The best
methods for computer vision work with operators to make them more
efficient and reliable. Computer vision systems should be integrated into
the activities of a manufacturer to identify any move in a process that
guides an operator through complicated job orders [53–55]. As corpo-
rations aim to improve efficiency and quality management, more com-
panies are searching to reduce unplanned downtime. Increasing
dependency on machine learning means that machine vision technology
plays an integral role in collecting and converting the real world into
networked digital data [56–58]. These data can be analysed and stored in
real-time for productivity enhancement, quality levels maintained and
waste reduction, enabling companies to increase operating performance
in a period of constant improvement. Industries open up possibilities for a
higher profit margin as their non-adopted counterparts lag. It can help
quality control in-line by providing supervision at the process level as the
operator functions. Some programs can also track and identify operators'
actions over time, enabling engineers to gain more visibility [59–61].
This technology enhances 3D scanner capabilities, which uses lasers
to trace the object's surface and digitalise it in a dot cloud representing its
3D copy. This data stream is often forwarded downstream to a device for
analysis. Companies that are implementing robotic control MV can see
their productivity, reliability, and output rise exponentially. It certainly
facilitates the development of demand for their customers and new
sources of income for themselves. When companies grow more dynamic,
resource control is interlinked more directly with the viability of an
organisation. The use of MV in many sectors enables more accurate
Fig. 3. Collaborative Features of Machine Vision for implementing Industry 4.0.
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manufacturing that eliminates pollution and reduces global demand. The
digital copy generated by the smart scanner is used by an automated
device to perform simulations to establish the maximum use of the
content. MV can extract the cumulative data over time for process
monitoring [62–64].
MV contributes significantly to the manufacturing sector by providing
automatic inspection capacity under quality control procedures. A good
practice is a visual inspection on a production line or packing line [65,
66]. Smart cameras perform inspection tasks and deliver a pass/fail result
to the control system, to computer-based systems of multiple cameras. In
combination with the predictive process management techniques, vision
inspections should also be used to track important metrics and analyse
patterns in these measures [67–69].
Technology has a significant influence in any step of the production
chain, from machine vision in warehouses to advanced robotics in
research and development laboratories. The developments in
manufacturing have contributed to reducing manufacturing errors,
improvement in product efficiency, increased versatility, reduced time
and costs, and increased productivity [70,71]. It is essential to optimise
the process with extensive data analysis based on input from several
different kinds of process monitoring sensors in the smart factory of the
future. These include primary and intelligent vision sensors, as well as
more advanced vision subsystems or systems. MV has become the most
common and benefited industry during the last decade, particularly in
the manufacturing sector [72–74].
MV allows computers to distinguish objects, interpret real-life scenes
and events. Deep learning is often aided by other methods that improve
its usefulness in some contexts. In other words, cameras can see and
inform people about fire observed or quality problems diagnosed in
manufacturing lines, count items on conveyor belts, examine medical
photographs, observe structures and inspect building environments [75,
76]. In automated production, image processing systems built around
industrial cameras are now an essential component. Industrial vision
cameras are used in all sectors and are an integral component of ensuring
reliability and high-quality performance in the entire manufacturing
process, from testing of raw materials and control of production to final
inspections and quality assurance. Image capture and analysis is crucial
M. Javaid et al.
factor in collecting the required information for Industry 4.0. Along with
increasing networking capacities, machine vision imaging systems open
up various new technologies and develop Industry 4.0 [77–89].
MV is an automation device where a camera is used to record any
action on a mounting line. The camera is designed in this situation to
determine the object's height, form, and colour. When implemented
strategically in the smart factory, MV systems are most effective as it
improves human and digital performance. The task of barcode scanners is
crucial in production. Barcode scanners have replaced the old paper and
pencil sorting approach. Since introducing barcode scanners, manufac-
turers have had various advantages, from smooth operations to reduced
time and costs to minimal errors to lowered stress levels [81–83].
6. Smart technologies for practising Machine Vision in Industry
4.0 environment
Fig. 4 exemplifies the numerous intelligent and advanced technolo-
gies and theories proposed under MV for its proper realisation in Industry
4.0 environment. It denotes several tact and traits, namely as; digital
electronics, lighting science, theory of sensors, system engineering, in-
dustrial and mechanical engineering, concepts of optics, throughout the
control of the quality, etc. to overall enhance the practicality of machine
vision through its implementation and realisation in the culture of in-
dustry 4.0 [84–86].
In the industrial sector, new-age innovations have always been at the
foremost. Thus, manufacturers innovate and revolutionise many activ-
ities leveraging new technological innovations in production. Similarly,
in manufacturing, machine vision technologies address big problems
facing businesses, helping them achieve benefits like greater yields,
better quality of performance, and lower financial costs [87,88]. The
rendering of images in 3D has continuously expanded by computer vision
technologies. Various modules have expanded in recent years, and these
components are increasingly sophisticated and tailored for specialised
applications, including robot guidance, high-speed imagery, and surface
profiling [89,90].
In contrast to traditional vision techniques used before, where a user
manually intervened in the definition and test of individual models and
functions, machine vision is more sophisticated and efficient. Machine
vision is used in a range of manufacturing procedures, such as content
Fig. 4. Illustration of machine vision technologies for industry 4.0.
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inspection, object identification, pattern recognition, and electronic ex-
amination of components, along with signature recognition, operating
characteristics, and currency. The view of the machine is generally
connected to the visibility of a screen. The term computer vision is
applied to the technologies used to digitise an image, manipulate the data
and perform various operations on a computer. A framework for viewing
a machine uses a robot sensor to display an object via a screen [91–93].
The industrial view of machines means low cost, reasonable accuracy,
high robustness, high mechanical reliability, and consistency in tem-
perature. Vision machine systems depend on digital sensors shielded by
specialist optics in industrial cameras for computer hardware and soft-
ware to store, interpret, and calculate different decision-making char-
acteristics. It uses cameras, typically in commercial or manufacturing
environments, to inspect and interpret objects automatically. The data
collected will then be used to monitor a method or production process.
The camera may be coded to verify whether or not the object's location,
colour, size, or form is present [94,95].
MV is becoming increasingly common in industrial automation en-
vironments and more widely employed in other industries, such as
defence, autonomous vehicular, food processing, packaging, logistics,
and robotics and drones. Computer vision can be combined with tech-
nology, such as deep learning and machine education, to understand data
better and optimise business performance [12,18]. MV has gathered
different meanings for what it is and how it does. Note that vision by
computer is not related to image processing, which is a method in which
the result is an image [96–98]. Thus, to understand the information
captured in the machine view, the identification, location, and guidance
of the subjects captured by the machine view system are interpreted as a
type of data. The technology can be used with a sensor that colours the
images and when objects are inspected and sorted [99,100].
In order to retrieve the necessary information and decide what to do
with the image, machine vision applications and programs would then
use different processing methods. This usually involves sending the pic-
ture to the next phase, routing it to a separate process, or deleting the
object from the output or delivery chain. The approach is programmed to
adapt depending on the role and use of these technologies in the system
and on the type of equipment the vision system will require. Specific
devices only need a few components, while others need many parts of the
same component in the production line or device [101,102].
M. Javaid et al. Sensors International 3 (2022) 100132

Table 1
Machine vision applications in industry 4.0
S Applications Description
No

1 Inspection Instead of human inspectors, several factories use MV because it is ideally suited to repeated inspection activities. It is quicker, more
objective, and continually functioning. MV systems can inspect thousands of parts per minute and more accurately and precisely provide
inspection results than humans. Manufacturers can save money and raise profits by cutting errors, increasing returns, enabling compliance
with regulations, and monitoring MV parts. MV may use Colour sensing pixels for machine vision, and sometimes pixel arrays are even more
prominent. In order to determine the dimensions, locations of the border, motion and relative position of components, software tools are
applied to the captured images. Many different ways to add lighting to the picture are available. When creating a computer viewing system,
the direction the light comes from, its magnitude, and wavelength relative to the target colour are all essential factors.
2 Increase data collection Combining MV with automation systems increases data collection efficiency and quantity and makes the intelligent plant possible. These
efficiency additional data are used in applications for quality assurance, waste minimisation, and protection at the more incredible output speed. For
the company's image and financial performance, the production of a reliable product satisfies the specifications of its customers. The
incorporation of MV to distinguish differences in production in real-time is improved in the era of Industry 4.0.
3 Quality improvement The 3D scanner watches products constantly during development and avoids wasting whole batches as a practice instead of waiting for
manual batches to be tested or examined. Many companies now incorporate 3D quality improvement computer vision. 3D scanners provide
precise product dimensions at each point in plants that produce products with complex dimensions, such as paver blocks, wood and tube
pipework. The operator will get instant notifications and shut down the manufacturing line, as can unacceptably differences in product
measurements.
4 Share of useful information MV continues to enhance the sharing of accurate and helpful information with the material processing devices, production lines, and
inspection stations. A manufacturing environment ensures that equipment and humans perform well with fewer bottlenecks, overruns, and
more disturbances. Human beings and machines work together on the production of an automobile component in order to obtain raw
materials, evaluate their content, transfer them to a processing plant and pass them through the production point. It enhances productivity in
any department, such as installation, and ensures consistent higher output standards.
5 Quality testing MV is gaining interest in automating quality testing. It helps employers simplify and boost outcomes from the quality assurance process in
certain modern production conditions, even without losing human employment. This digital test stations address high-priority work whilst
workers learn more demanding skills from their cognitive point of view. In industrial manufacturing, this is attributed to changes in the
vision of the computer and the desire to avoid inefficiency, inaccuracy, and waste as much as possible from industrial manufacturing.
6 Intelligent production The role of MV in industrial automation and intelligent production is revolutionised by deep learning. Integrating deep learning has made it
possible to adapt machine vision applications to production variations autonomously. The value proposition for the view of the computer has
been significantly increased by improved operating efficiency, speeding the inspection process, and increasing reliability. MV integrates
machine learning in several instruments with unparalleled ability to observe and view consumer and industrial hardware surroundings. The
technology, along with robotics and high-speed networking, in an industrial context leads to Industry 4.0. This delivers new methods of
conducting low-waste manufacturing operations with high performance.
7 Simplify certain processes MV is a superior technology that helps manufacturers simplify specific processes where many products need to be tested on a production line.
Most producers rely on an exceptional quality for their output, and thus, it is essential to have a mechanism that automatically identifies any
variations. The most general use of MV systems is applied for tooling and details placement on the production lines. The machine determines
exactly where an entity or instrument has been located and sends these coordinates to the robot. It is typically used for application selection
and placement. Identifying abnormalities is used to study new photographs and equate them to existing data sets to identify defects in
production facilities, production lines, etc., and avoid harmful conditions.
8 Die-cutting The manufacturing industry can implement MV systems to do rotary die cutting as accurately as laser cutting to cut any pattern. The device
would direct the die-cutting mechanism to perform cutting into the computer vision system correctly. Some production processes take place
in critical temperatures, so material deterioration is normal. Constant equipment inspection is carried out manually by the manufacturers.
However, computer programs will track the equipment continuously using different metrics. If the deviation from the metrics indicates
corrosion, the respective managers will warn the computer vision systems to conduct maintenance proactively.
9 Quality assurance The quality assurance of machinery with vision ensures the precision and quality of produce, reducing operating losses from waste materials,
are met every time. A manufacturing line has traditionally involved human involvement and assessment of crucial stages. The beginning of
Industry 4.0 provides an integrated approach that allows computers to decide on the data collected from the 3D scanner with the assistance of
machine vision. The effect is an intelligent and cleaner farm, which reduces the consumption of labour and increases production.
10 Control employee movement Industries employees operate in challenging circumstances, which mean that the risk of injuries is even greater. The production facilities
must comply with safety requirements implemented by regulatory bodies. Firms that do not comply with these standards must face sanctions
even though manufacturers have mounted cameras to control employees' movement inside the plant to maintain safe conditions. The manual
procedures may be mistaken, and this may have severe effects. A computer view controlled by AI can be a suitable solution. MV technology
watches the production site continuously from the entrance, in the site, and the exit.
11 Supervision The MV system will alert supervisors and personnel to the occurrence and injury intensity of an ongoing accident to stop development in that
particular field and proactively guarantee the welfare of workers. It is necessary to count the number of fabricated parts before being
packaged in a container in some manufacturing firms. Another use case for machine vision inspects the damages to the box itself when the
products are correctly packaged. Items can go safely only once in a while to consumers. Before exiting the factory, computer vision devices
will proactively diversion any faulty packaging. Barcode authentication is another significant factor in which most goods are subject to
barcodes. The packaging department reviews the accuracy and reading of written barcodes.
12 Barcode checking Cross-checking bar codes for thousands of items require much manual time and are inefficient and error-prone. MV devices can quickly check
barcodes and identify defective barcodes. This system can help to count stocks, retain warehouse inventory status and automate and warn
management. The MV systems can prevent errors in inventory counting. This solution can help inventory managers identify warehouse items
by using computer vision technology based on barcode data.
13 Minimise production faults MV applications allow businesses to increase the quality of their goods, minimise production faults, reduce production costs and meet
customer demands with products of the highest quality at a reasonable rate. The fundamentals of MV software and interpreting the industrial
barcode will help to ease inspections, maximise read speeds, and make the production line's results more accurate and repeatable. In the
advancement of industrial robotics, MV has played a vital role, and the two are rapidly combined. MV enables a robot to see in a way what it
is doing. This technology helps a robot adapt to challenges in its world by realising which tasks it has to complete.
14 Identify defects The manufacturer can identify defects and fractures in a physical object through MV systems. In addition, these devices can accurately verify
exact and reliable measurements of materials and components. MV devices take commodity and goods pictures. These images are then sent to
a computing computer. The staff concerned receives information on any errors. In order to satisfy the consumer, producers are capable of
implementing electronic inventory testing machines and accurate quality management.
15 Tracking and reporting This technology is also suitable for tracking and reporting. The high dynamic range of the vision sensor permits service in challenging
lighting conditions while providing far less data than a conventional framework-based solution and reduces the computational burden of
scene analysis. MV automatically analyses and inspects manufacturing lines using imagery, which is used to track processes, check,
(continued on next page)

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Table 1 (continued )
S Applications Description
No

estimation, robot guidance and other functions. It requires a complete approach from image acquisition to a management data system
interaction.
16 Monitor devices The MV system automatically acquires an image to provide desired information and monitor devices or systems according to industry
requirements. It is an automated method by which quality management information is retrieval from digital pictures. Most factories are best
suited to repeated check activities with automatic MV instead of human inspectors. It is quicker, more objective, and continually functioning.
MV extends to all systems where computers are operationally driven by a mixture of hardware and software when executing the tasks
dependent on image capturing and processing.
17 Visually recognise pictures MV provides robots with the ability to visually recognise pictures and capture and take decisions the same way humans do. These
progressions have made it possible for a machine vision to automatically identify specific patterns in various images and execute the action
needed. Machine vision is one of AI's primary industries that seek to have computers that have a human-like vision capability to capture,
recognise, and decision-making images as in the real world. These progressions have made it possible for a machine vision to automatically
identify specific patterns in various images and execute the action needed.
18 Robotics and production lines MV is commonly accepted for use in robotics and production lines. The use of this technology reduces the role of humans in different
procedures. Implementing MV in collaboration with other technologies like conveyors may insert them into a dangerous environment or in
clean rooms that could contaminate humans. The vision systems will increase production efficiency due to human errors and maintain the
quality control of all goods along the chain. Machine visioning device uses algorithms to classify programmed features that also trigger a
series of actions depending on the results.
19 Monitoring and controlling MV devices have many other uses in addition to content inspection. These devices are also used to monitor and control visual stock, such as
visual stock reading and counting barcodes and testing components at different points in industrial production. A robot viewing device consists of various
important elements, including a camera capturing an image, which supplies and communicates the result to the processing mechanism. It is
vital how these fundamental components combine to make every machine vision device reliable and deliver results.
20 View complex design In the automotive sector, as the industry is gradually changing from product standardisation to product specialisation, machine vision is
likely to increase. A typical computer viewing system is complex to design as several industrial sectors cover, and criteria are different
depending on consumer requirements. The demand for machine vision is divided into a general vision based on implementation. Robots can
accommodate a growing range of product variations as part styles can be modified by simply modifying the control and program without
stopping the development process.

Vision by the computer is a skill and not an enterprise like other skills
like learning by machine, deep learning, and neural networks. It is a
capability that can be embedded with other systems and processes to
enhance market performance and support the industry. As companies
gradually strive to simplify business operations through the adoption of
automation capabilities such as computer vision and robotics, the ap-
plications of MV are rising and are never going to slow down. Automation
and robotics exhibit real strength and capacity because companies cannot
satisfy decreased labour demands of industry and consumers [103,104].
In the manufacturing sector, MV has become critical. The need for MV
technology is crucial for increased quality control requirements. MV
builds on technologies and expertise in automatic camera inspection and
testing for applications such as measurement, text interpreting, process
control, and robot guidelines. The vision system can consist of several
sensors, often installed over an assembly line, inspecting products,
recording data, reading labels, direct products and more [105–107].
Due to the growing quality demands of manufacturers and con-
sumers, machine vision has become a core technology in production and
quality control. To visually inspect objects, translate products, and con-
trol robots in real-time, MV uses industrial imaging with cameras
installed over manufacturing lines and cells. The technology of MV has a
significant effect on the manufacturing sector and industry. With the
latest wave of digitalisation entering the market, this technology is
supposed to offer businesses even greater hope. In the context of indus-
trial production operations, the emphasis of MV is mainly on computer
vision or by inspection or other sensitive control inputs [108,109].
The ability to do an imaging examination on equipment is usually an
MV. It allows industrial machinery to perform activities such as pro-
duction and quality control. This technology is a core factor of Industry
4.0 and supports industrial automation systems by performance
improvement, inventory improvement, and product identification, and
finally, quality improvement [110,111]. This technology supports many
new developments, such as artificial intelligence, robots, and clever
brass. As a transformation technology, MV in the supply chain provides
reliable, automatic logistic control of the outputs. Zero shipping errors
and maximises workflow productivity by automated data acquisition
reduce operating costs and improve profitability. While the exposure of
the supply chain is constant, the MV methods will be used by producers
and shipping firms for the next few years [112,113].
7. Machine vision applications for industry 4.0
MV is helpful for image-based automatic inspection. Its applications
have become essential in Industry 4.0 and continue to evolve in various
sectors. The Vision of machines is presently used in many fields,
including automobile, pharmacy, military, food and drink, electronics,
etc. MV uses include fault detection, an inspection of product and
packaging, recognition and monitoring of parts, and measurement
[114–116]. These technologies improve efficiency, greater productivity,
a decreased footprint, and low manufacturing costs. During the predic-
tion era, the automotive sector holds the biggest MV markets. The MV
technology in the automotive industry offers increased precision in
crucial operations, including the placement of pieces for assembly, such
as doors and panels. Due to the lack of skilled workers and the reduction
in automotive manufacturing costs, automotive industries are more
focused on automating their manufacturing processes. Therefore, the
automobile industry will hold the most significant demand in the future
for MV [117–120]. Table 1 discusses the significant applications of ma-
chine vision for Industry 4.0.
MV will be everywhere shortly, bringing to the Internet of things in
Industry 4.0. The vision of the computer is a series of innovations that
enable machines to become more aware of their environment. It makes it
easier to recognise and make decisions dependent on knowledge of im-
ages [121–125]. Industrial equipment uses highly faithful cameras to
capture digital environmental and workpiece pictures that utilise com-
puter vision. The pictures can be taken on a robot inspection station and
an autonomous led vehicle. MV uses incredibly advanced model recog-
nition algorithms to evaluate its location. Part of the barcode is shaded;
reading can cause an error when unavailable or vice versa. The required
lighting is crucial for correct MV when manual inspections are carried out
[126–129].
MV provides primary importance to producers for better protection to
staff and safeguards the environment. Production organisations improve
and offer the best available support in terms of safety programs. Not only
can MV help manufacturers simplify the production operation, but also
increase employee safety. These devices can collect photos from the plant
with real-time image processing. This results in helpful knowledge about
when employees are in life-threatening and dangerous conditions. MV
devices would inform the concerned about the hazardous site situation to

7
M. Javaid et al.
take the precautions required in due course. The vision systems for ma-
chinery will thus help manufacturing industries predict environmental
threats or risks in due course, avoiding potential malfunctions
[130–132].
8. Discussion
The MV technology takes multiple images from different angles to
provide a 3D rendering as components pass around the production plant.
These identify any defective threading or slight deviation from the
specification when paired with and fed into AI algorithms. This tech-
nology is highly credible in manufacturing sectors such as automobiles,
electrical circuits, oil, gas, energy, etc. It offers operators and engineers a
tool for improved data collection, empowering operators and bug-
resistant assemblies. As part of Industry 4.0, the manufacturing in-
dustry has adopted different automation technologies. The automotive
sector uses numerous emerging technologies such as artificial intelli-
gence, machine learning, the internet of objects, computer vision, ro-
botics, etc., to modify the production of goods as part of industrial
automation.
In the product and component assembly in the production area, MV
systems play a significant role. Much of the automotive industry has
implemented MV for fully integrated product assembly and management
processes as part of the transformation of Industry 4.0. The computer's
vision system precisely controls the mounting process based on designs.
These systems track robotic arms and staff in the assembly line and direct
them continuously. The computer-driven vision program compiles in-
formation from cameras and uses machine learning techniques, analyses
data sources and identifies faults, and provides the proportion of de-
viations based on predefined quality specifications. This data can be used
to trace reverses in manufacturing line processes. In a manufacturing
line, a machine vision inspection device is used to carry out human tasks.
In this case, a complete 3D model of modules and connector pins are
constructed using a high-resolution image framework.
For some time now, robots have become part of the production in-
dustry. AI and computer vision technologies are used to control robots.
Robots can take pictures of all machinery quickly. The pictures and any
additional equipment information are then sent to the cloud to analyse
and sort. The data will allow producers to obtain valuable information on
whether or not this particular device will malfunction. To improve
customer loyalty, suppliers must provide their customers with the best
quality goods. It is possible for an MV to automatically identify specific
patterns in various images and execute the action needed.
Modern MV technologies are essential to automation and quality
assurance in the automobile industry. That is why longevity and ease of
service are of particular significance. Systems also have to be easily in-
tegrated into battery production because of short rise times. Combined
with machine learning, MV technology and robotics deliver various new
opportunities for realising state-of-the-art ideas like the smart factory.
MV applies basically to picture-based technologies used in automotive
and manufacturing applications, including recognition, inspection, sort-
ing, and measurement. It is also used for robotics guidance. The scope for
inspection in computer vision grows exponentially because of advances
in deep learning techniques. Machine vision can now perform hard or
impossible tasks to execute a few years ago based on state-of-the-art
guidelines.
9. Future of machine vision
MV in manufacturing will be a very multifaceted technical stack like
any technological approach. This segment will examine some of the most
commonly used powered software. It has a library of functions and al-
gorithms that will allow users to read images, pre-set the camera to
normal, reduce optical distortions, and measure the motion of an object.
Industries that give automation preferences are gaining strategic
advantage over peers with all the benefits realised from machine vision
8
Sensors International 3 (2022) 100132
and Industry 4.0. In the coming years, this will further guarantee future
economic prosperity and peace. Computer vision integrates machine
learning in several instruments that have unparalleled ability to observe
and view their surroundings for consumer and industrial hardware.
These developments, along with robotics and high-speed networking, are
added to a modern technological revolution in the context of industry
4.0. This also delivers brand new methods of conducting low-waste
manufacturing operations with high performance. The vision of the
machine affects output, perforation, and mining. It includes freight and
supply chain management, quality management, materials handling,
protection, and a range of other processes.
10. Conclusion
MV is the approach of industrial automation and related technology.
It can be implemented for automated visual inspection, which can
overcome several business problems. The technology of machine vision
replaced human quality checks steadily. It offers different precision and
durability in the identification of objects. MV is beneficial for Industry
4.0 to improve accuracy, productivity, and overall efficiency to increase
the traceability of their goods. Here industrial equipment uses highly
faithful cameras to capture digital environmental pictures or a workpiece
to utilise a computer vision system. Thus, MV, particularly in the
manufacturing sector, has gained immense prominence. Manufacturing
companies can take advantage of greater versatility, reduced product
errors, and improved overall technological efficiency. When manufac-
turers deal with the production of large-scale products, many primary
machines and heavy equipment are used. In order to prevent equipment
downtime, certain pieces of equipment are tracked constantly. MV is
beneficial for freight, supply chain, quality assurance, inventory pro-
cessing, safety, and a range of other vertical procedures, and soon, it will
be everywhere in production.
Declaration of competing interest
None.
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