AI-Powered Quality Control Transformation
How an AI vision system drove a 60% reduction in product defects and a 25% increase in line throughput for a Tier 1 automotive supplier.
The Story
Precision Auto Parts, a critical supplier of complex components to major OEMs, was facing a significant challenge with quality control. Their manual inspection process, reliant on human operators, was struggling to keep pace with increased production demands. This resulted in inconsistent defect detection, leading to an unacceptably high rate of scrap, rework, and occasional customer returns. The manual process was not only costly but also a bottleneck that limited overall line throughput and posed a risk to their reputation for quality.
The leadership team recognized that to meet tightening OEM quality standards and improve profitability, they needed to move beyond human inspection. The strategic goal was to implement a fully automated, highly accurate quality control system that could operate at the speed of their production line, catching microscopic defects that the human eye might miss.
What Did Medha Soft Do
Medha Soft was engaged to deliver an end-to-end AI-powered quality control solution. Our team of AI and manufacturing experts worked closely with the plant floor engineers to design and deploy a system tailored to their specific components and production environment. The solution was built on our AI-Hybrid framework, ensuring a robust and scalable implementation.
Custom AI Model Development
We collected thousands of images of their components, including both good parts and known defects. Using this dataset, our data scientists trained and validated a custom computer vision model capable of identifying defects like cracks, scratches, and deformities with over 99.5% accuracy.
Hardware Integration & Edge Deployment
We designed and installed a camera and lighting rig on the production line. The AI model was deployed on an edge computing device, allowing for real-time inference and decision-making directly on the factory floor without requiring constant cloud connectivity.
System Integration & Workflow Automation
The vision system was integrated with their existing Manufacturing Execution System (MES). When a defective part is identified, the system automatically triggers a pneumatic arm to divert the part to a rejection bin and logs the defect type, providing valuable data for process improvement.
Data Analysis Chart
The chart below highlights the sharp decline in the defect rate (parts per million) after the AI vision system went live, demonstrating its immediate impact on quality.
Chart Caption: Defect Rate (PPM) Before and After AI System Implementation.
The Results
The AI-powered quality control system delivered transformative results, fundamentally improving product quality, operational efficiency, and profitability.
60% Reduction in Product Defects: The system's high accuracy virtually eliminated defective parts from reaching the final packaging stage.
25% Increase in Throughput: By automating the inspection bottleneck, the overall production line speed could be increased significantly.
$1.2M Annual Cost Savings: The reduction in scrap, rework, and manual labor costs resulted in substantial and recurring financial savings.
Customer Reviews of the Case
Medha Soft's AI vision system has been a game-changer for our plant. It's more accurate and faster than any human inspector. The data we're getting has also allowed us to find and fix the root causes of our quality issues. This wasn't just a tech project; it was a business transformation.
Michael Rodriguez
Plant Manager, Precision Auto Parts
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