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What is the difference between offline AOI and online AOI? | POE
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What is the difference between offline AOI and online AOI?

Automated optical inspection (AOI) is an inspection process in PCB manufacturing to detect defects in solder joints, components, and circuit patterns. AOI systems use cameras combined with software to accurately inspect PCBs. According to how they are integrated into the production line, AOI systems are divided into offline AOI and online AOI.
Home >Blog >PCB/ PCBA Blog > What is the difference between offline AOI and online AOI?
What is the difference between offline AOI and online AOI?
15 January 2025
Views: 7
Automated optical inspection (AOI) is an inspection process in PCB manufacturing to detect defects in solder joints, components, and circuit patterns. AOI systems use cameras combined with software to accurately inspect PCBs. According to how they are integrated into the production line, AOI systems are divided into offline AOI and online AOI.

What is offline AOI?
Offline AOI is an independent inspection system that is not directly integrated into the production line. After the PCB comes off the production line, it is manually loaded into the machine for inspection. The inspection of offline AOI is carried out as a separate step, which is suitable for sampling and small batches. And because it is a stand-alone system, it can be placed anywhere in the factory.

offline AOI

Advantages of offline AOI
1.Offline AOI systems are usually cheaper than online AOI systems.
2.Ideal for small-batch production and design adjustments.
3.Offline AOI allows more time to analyze defects and fine-tune inspection parameters without affecting production.

Limitations of Offline AOI
1. PCBs must be loaded and unloaded manually, increasing labor costs and risks.
2. Less efficient: Since it is not integrated into the production line, quality checks are not performed continuously during production.

What is Online AOI?
Online AOI is directly integrated into the production line, placed after solder paste printing, component placement, and reflow soldering processes, and inspects PCBs in real time as they are manufactured. It is part of the production line, ensuring seamless quality control, suitable for high-quality manufacturing in large quantities.

Online AOI

Advantages of Online AOI
1. Inspection is performed during the production process, fast and corrective measures can be taken immediately.
2. Detect defects early and increase production.
3. Online AOI reduces labor costs.

Limitations of Online AOI
1. Online AOI systems cost more to purchase and implement than offline systems.
2. Not very suitable for small batches and frequent program changes.
3. Online systems require dedicated space on the production line.

Key Differences Between Offline AOI and Online AOI

Aspect Offline AOI Online AOI
Integration Standalone system Integrated into the production line
Inspection Timing After production During production
Best Use Case Sampling, prototypes, small batches High-volume production
Cost Lower system cost Higher initial cost
Flexibility High (easy to adjust for new designs) Low (requires setup changes for new designs)
Efficiency Slower, requires manual handling Faster, automated inspection
Defect Detection Detailed, but slower Fast, but may require post-inspection verification
Which one should you choose?
The choice between offline AOI and online AOI depends on the specific requirements of your manufacturing process:

Choose offline AOI if:
You are producing small batches or prototypes.
Cost is the main consideration.
Flexibility and detailed analysis are more important than speed.

Choose online AOI if:
You are producing in large quantities.
Real-time quality control is critical.
You want to reduce overall defect rates and improve efficiency.

Conclusion
Both offline AOI and online AOI play an important role in ensuring PCB quality, but they meet different production needs.
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