Case Studies
Ground Breaking Innovation in Visual Quality Inspection using AI
Our client is one of the top automotive makers in the world and is known for the quality and durability of its vehicles. Given the client’s strict adherence to the Six Sigma principles in its manufacturing processes, the aim of the project was to elevate quality standards in the most optimal way possible.
Industry
Automotive
Services
AI Module
Computer Vision Module
Technologies
AI / Computer Vision
Chakra UI
Tailwind CSS
Python
Fast API
Manual inspections are prone to inaccuracies, distractions, and incorrect data entries, all of which can compromise the production quality and result in costly rework or delays especially in manufacturing plants, which demand high levels of precision and minimal defects. By automating the external lights inspection process through an AI/Computer Vision module, the project minimizes manual labor, ensures consistent and accurate data collection, and supports the client’s goal of achieving flawless operational standards
Problem Statement
Solution
The project is in its initial phases and remains an ongoing initiative. The initial phase centers on developing and testing core AI-driven inspection capabilities and focusing on a major on/off inspection point for the external vehicle lights. The implemented solution involves an automation system designed to enhance the accuracy and efficiency of inspecting external vehicle lights. High-resolution cameras, using RTSP (Real-Time Streaming Protocol), are installed to capture and record the condition and functionality of the lights, enabling precise and automated identification.For the front end, the system utilizes React.js, along with Chakra UI and Tailwind CSS, to create a user-friendly interface that provides seamless interaction and data visualization capabilities. The backend leverages Python for AI and computer vision algorithms, enabling robust and intelligent inspection capabilities. Moreover, FastAPI is used for backend development to ensure high-performance data handling, efficient processing, and smooth communication between the front end and AI modules.
Impact
This solution marks the first AI implementation within the client’s manufacturing plant, introducing unprecedented automation capabilities to their processes. Prior to this project, manual inspections were the standard practice for external vehicle lights, making this AI-driven, automated inspection a groundbreaking advancement. This is a major leap forward for the company in efficiency and accuracy, setting a new benchmark for innovation and operational excellence within the plant.
Results
The system will automate the detection of light functionality, starting with on/off inspections and eventually expanding to check brightness, flashing conditions, and emblems across all vehicle models. This will streamline the manufacturing process, minimize production delays, and ensure compliance with the company’s standards, ultimately improving the overall quality and efficiency of the production line.
Improvement in KPI's
Reduction in Inspection Time
50% - 30%
01
Decrease in Inspection Time
90% - 95%
02
Increase In Production Throughput
10% - 20%
03
Accuracy of AI Inspection
98% - 99%
04
Reduction in Rework and Defects
80% - 90%