How AutoTech Components Reduced Production Waste by 40% With Custom Computer Vision
Automotive Manufacturing
200-500 Employees
Detroit, MI
Background
AutoTech Components specializes in precision-machined engine parts for major automotive brands. Their reputation hinges on delivering flawless components with microscopic tolerances. For years, they relied on a team of human quality assurance (QA) inspectors to manually review parts on the assembly line. As production volumes scaled to meet new electric vehicle (EV) contracts, the manual inspection process became a critical bottleneck, unable to keep pace with the high-speed conveyor systems while maintaining their strict quality standards.
The challenges
As the company ramped up production, the limitations of manual inspection became apparent. The CEO and the Head of Production, Sarah Jenkins, recognized that human inspectors, while skilled, suffered from fatigue after long shifts, leading to inconsistent results. The “false acceptance” rate (bad parts getting through) began to creep up, risking contracts with Tier-1 OEMs. Furthermore, the inspection process was forcing the assembly line to run at 70% capacity, costing the company millions in potential revenue. They needed a non-invasive, high-speed automated solution that could integrate with their existing conveyor belts without requiring a factory redesign.
“The computer vision model didn’t just match our human inspectors; it surpassed them. We are catching microscopic hairline fractures that were previously impossible to see with the naked eye at speed.”Sarah Jenkins
Head of Production
The Solution
We designed and deployed a custom edge-based computer vision system tailored to AutoTech’s specific defect types.
The Result
AutoTech successfully moved from a manual, sampling-based inspection process to 100% automated inspection for every single part leaving the line.
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