Niccolò Ferrari

Niccolò Ferrari, Oligert Osmani, Evelina Lamma

Industrial visual anomaly detection is usually one-class: normal images are abundant, while defects are rare, heterogeneous, and often unavailable during system design. PatchCore-style retrieval suits this setting because it scores test images from a memory bank of normal patch features, but the standard Euclidean geometry ignores feature correlations and its offline construction materialises the full patch pool before subsampling. We introduce Mahalanobis PatchCore, a covariance-aware, streaming-compatible extension of PatchCore. Its artificial intelligence contribution is a retrieval detector that estimates a regularised covariance model in reduced feature space and whitens embeddings, so Euclidean nearest-neighbour search after transformation implements Mahalanobis retrieval. A bounded-memory, re-iterable training pipeline builds the memory bank without storing all normal patches at once, using incremental dimensionality reduction, online covariance estimation, and streaming aggregation. The engineering application is automated industrial inspection, where visual anomaly detection must remain accurate under practical memory limits. We evaluate the method on a public 15-category industrial anomaly-detection benchmark and three industrial datasets covering blow-fill-seal strip-ampoule meniscus inspection, amber-glass-ampoule bottom inspection, and lyophilised-cake vial inspection. Mahalanobis PatchCore preserves most offline PatchCore image-level performance on the public benchmark while reducing peak memory from 5.41 to 2.78 GB, and improves the selected industrial mean image area under the receiver operating characteristic curve from 0.981 to 0.986.

Niccolò Ferrari, Michele Fraccaroli, Evelina Lamma

Anomaly detection is nowadays increasingly used in industrial applications and processes. One of the main fields of the appliance is the visual inspection for surface anomaly detection, which aims to spot regions that deviate from regularity and consequently identify abnormal products. Defect localization is a key task, that usually is achieved using a basic comparison between generated image and the original one, implementing some blob-analysis or image-editing algorithms, in the post-processing step, which is very biased towards the source dataset, and they are unable to generalize. Furthermore, in industrial applications, the totality of the image is not always interesting but could be one or some regions of interest (ROIs), where only in those areas there are relevant anomalies to be spotted. For these reasons, we propose a new architecture composed by two blocks. The first block is a Generative Adversarial Network (GAN), based on a residual autoencoder (ResAE), to perform reconstruction and denoising processes, while the second block produces image segmentation, spotting defects. This method learns from a dataset composed of good products and generated synthetic defects. The discriminative network is trained using a ROI for each image contained in the training dataset. The network will learn in which area anomalies are relevant. This approach guarantees the reduction of using pre-processing algorithms, formerly developed with blob-analysis and image-editing procedures. To test our model we used challenging MVTec anomaly detection datasets and an industrial large dataset of pharmaceutical BFS strips of vials. This set constitutes a more realistic use case of the aforementioned network.

Niccolò Ferrari, Nicola Zanarini, Michele Fraccaroli et al.

Industrial visual inspection in pharmaceutical production requires high accuracy under strict constraints on cycle time, hardware footprint, and operational cost. Manual inline inspection is still common, but it is affected by operator variability and limited throughput. Classical rule-based computer vision pipelines are often rigid and difficult to scale to highly variable production scenarios. To address these limitations, we present a semi-supervised anomaly detection framework based on a generative adversarial architecture with a residual autoencoder and a dense bottleneck, specifically designed for online deployment on a high-speed Blow-Fill-Seal (BFS) line. The model is trained only on nominal samples and detects anomalies through reconstruction residuals, providing both classification and spatial localization via heatmaps. The training set contains 2,815,200 grayscale patches. Experiments on a real industrial test kit show high detection performance while satisfying timing constraints compatible with a 500 ms acquisition slot.