Case Study: Cross-Car Bar Smart Quality Inspection Precision in Automotive Manufacturing

In today’s fast-evolving automotive industry, maintaining the highest standards of quality is crucial.?

At ThirdEye AI, our vision inspection solution for cross-car bar is making a significant impact on the production process. Designed to detect defects and improve overall product quality, the solution is a key component in driving operational excellence for a leading tier-1 automotive component supplier to a global car manufacturer. With our commitment to innovative technology, we are helping automotive manufacturers streamline their inspection processes, ensuring safer, more reliable products while optimizing cost efficiency and productivity.

Challenges Faced by Component Suppliers During Quality Inspection

Manual Inspection Limitations: Human error in detecting small defects or weld shifts can compromise product quality and consistency, leading to increased rework and waste.?

Time-Consuming Processes: Traditional inspection methods can be slow, leading to production delays and higher labor costs, impacting overall efficiency.?

Inconsistent Quality Control: Ensuring 100% precision and repeatability in manual inspections is difficult, making it challenging to meet stringent quality standards.

Data Traceability Issues: Lack of real-time data makes it harder to trace defective parts.

High Labor Dependency: Lack of detailed, real-time data analysis can hinder traceability and quick identification of defective parts.

Customer Satisfaction Impact: Relying on manual inspections creates labor-intensive operations, limiting scalability and increasing operational costs.?

Vision Inspection of Cross-car bar (CCB):

Scope-

• Automated Hole Count????
• Hole Presence Absence????
• Weld Quality????
• Weld Presence Absence????
• Weld Measurement????
• Child Parts Visibility ?
• Child Parts Positioning????
• Hole Shift and Weld Shift

Solution Approach-

The vision inspection solution for Cross-Car Bar (CCB) leverages advanced technology to ensure high-quality defect detection and analysis. This approach ensures thorough examination of components while allowing for flexible adjustments based on evolving production needs, without requiring additional training.

• Robotic arm-based vision camera???
• Multiple inspection checkpoints??
• Analytics using AI-enabled Algorithms??
• Detailed report with defect analysis?
• Add new checkpoints in real-time with no training??

Value Delivered:

ThirdEye AI addresses key challenges in the automotive manufacturing industry by providing precise, real-time inspection solutions that eliminate quality control bottlenecks.

1. Detects weld shifts beyond 2mm.
2. Reduced inspection time from 180 to 100 seconds.?
3. Conducted 408 checkpoints, exceeding human capabilities.?
4. Achieved CMM-level precision and minimized errors.?
5. Ensured 99 % repeatability and 24/7 availability.
6. Scaled up operations with parallel installations, minimizing labor dependency.?

Stay tuned for more updates and insights as we continue to drive innovation and excellence in the automotive manufacturing industry. At ThirdEye AI, we're committed to pushing the boundaries of technology, delivering cutting-edge solutions that solve real-world manufacturing challenges. From enhancing operational efficiency to ensuring top-tier quality, we're paving the way for smarter, more agile production processes. Keep following us for the latest advancements and success stories.