Revolutionizing Quality Control with AI Vision
How an automotive parts manufacturer achieved near-perfect defect detection and increased production speed with Adhunik's AI solutions.
Client Profile
A leading automotive parts manufacturer producing precision components for major automotive brands. The company operates multiple production facilities with high-volume output requirements and strict quality standards.
The Challenge
The manufacturer was facing several critical challenges in their quality control processes:
Manual visual inspection processes that were labor-intensive and prone to human error
Inconsistent quality control results across different shifts and inspectors
Production bottlenecks caused by the inspection process limiting line speed
Increasing customer quality requirements and zero-defect expectations
High costs associated with quality control staffing and defect-related warranty claims
Our Solution
Adhunik implemented a comprehensive AI-powered visual inspection system:
Computer Vision Inspection
Advanced AI vision system using high-resolution cameras and deep learning to detect even microscopic defects.
Real-time Quality Analytics
Dashboard providing instant insights into quality metrics, defect types, and production performance.
Automated Defect Classification
AI system that categorizes defects by type, severity, and root cause to facilitate targeted improvements.
Continuous Learning System
Self-improving AI models that continuously learn from new defect patterns to enhance detection accuracy.
Implementation Process
Process Analysis & Camera Placement
We conducted a comprehensive analysis of the production lines and determined optimal camera placement for complete part coverage.
AI Model Training
We trained the AI models using thousands of images of both defective and non-defective parts to achieve high accuracy.
Pilot Line Deployment
We implemented the system on one production line, running it in parallel with manual inspection to validate performance.
Full Facility Rollout
After successful validation, we expanded the implementation to all production lines across the facility.
Integration & Optimization
We integrated the system with the manufacturer's MES and continuously refined the AI models to improve detection accuracy.
Results at a Glance
99.8%
Defect Detection Rate
45%
Reduction in Quality Control Costs
30%
Faster Production Line Speed
85%
Reduction in Customer Complaints
4
Month ROI
"Adhunik's AI vision system has completely transformed our quality control process. We're now able to detect defects that would have been impossible to catch consistently with human inspection. The increased production speed and reduced quality control costs have given us a significant competitive advantage, while the near-perfect detection rate has strengthened our reputation with customers."
David Kim
Quality Director, Automotive Parts Manufacturer
Transform Your Manufacturing Quality
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