Introducing ZUMBACH’s New AI-Driven SIMAC® Surface Testing System

Zumbach Electronic is advancing surface inspection technology with the launch of the next‑generation SIMAC® Surface Testing System, now empowered by AI‑driven Intelligence. Designed for cables, tubes and hoses, the new SIMAC® solution delivers a breakthrough in accuracy, adaptability and on‑line quality assurance. Built on deep‑learning innovation, the system moves beyond traditional defect detection to provide manufacturers with actionable insights, continuous learning capabilities and an unprecedented level of process transparency.

On‑line detection: Identifying defects at full production speed
At the core of the new SIMAC® platform is its artificial intelligence-based high‑performance detection engine, developed to recognise surface abnormalities instantly and reliably, with the following benefits:
• Detects surface defects inline at full production speed
• Requires no defect labelling, because it is trained entirely on defect‑free images
• Provides adaptive behaviour, automatically compensating for process drift
• Allows fast model recalibration for new production conditions
• Includes adjustable sensitivity, enabling a configurable precision/recall balance depending on customer requirements
This means that operators no longer need to manually tune thresholds or define defect rules. Instead, the deep‑learning engine continuously evaluates the product surface, flagging any deviations from expected patterns.

Intelligent classification: Knowing exactly what is wrong
Detection is only the first step. With SIMAC®’s new intelligent classification module, users also gain clarity about what type of defect has occurred. The system can:
• Automatically assign defects to predefined types
• Provide precise defect localisation on the product
• Support the introduction of new defect types, when combined with model retraining
• Offer adjustable sensitivity for enhanced precision or broader coverage
• Apply a “one‑for‑all” model, meaning a single trained model can serve multiple products
This unique AI-driven defect classification tells us exactly what is wrong, enabling engineers to better understand production issues rather than just reacting to alarms.
Continuous improvement: A system that evolves with production
One of the most forward‑looking capabilities of the new SIMAC® is its ability to evolve. The system’s continuous improvement framework allows it to become increasingly accurate, consistent and adapted over time. Key features include:
• Fast recalibration of the detection model
• Re‑classification and correction of mis‑detected defects
• Incremental enrichment of training datasets
• Full retraining when introducing new defect categories
• Ongoing optimisation of thresholds and system behaviour
Because the new SIMAC® is not based on fixed rules, it evolves with production, positioning itself as a future‑proof solution that grows alongside customer processes, raw materials and quality requirements.

Advanced process analysis: Turning data into insights
Beyond detection and classification, the SIMAC® introduces a powerful process analysis module that helps manufacturers understand not only what defects occur, but why. The module offers:
• Statistical monitoring of defect frequency and distribution
• Trend analysis over production length and time
• Correlation between defect type and position
• Identification of periodic or localised patterns
• Filtering of non‑critical defects based on type
With these capabilities, factories can trace recurring issues back to root causes, such as tooling wear, material inconsistencies or periodic mechanical vibration. The provision of filtering and statistical visualisations highlight how operators can quickly isolate relevant defect categories.

From detection to decision, instantly
The combination of AI‑based detection, intelligent classification, continuous learning and deep process insights transforms SIMAC® from a traditional inspection tool into a comprehensive decision‑support system. Operators can react faster, engineers can analyse more effectively and production managers gain reliable data for optimising output quality.
Zumbach’s next‑generation SIMAC® Surface Testing System sets a new benchmark for the industry: smarter detection, deeper understanding and adaptive performance that keeps pace with the dynamic environment of wire, cable, tube and hose manufacturing.