Complex Assembly Inspection Made Simple with AI Machine Vision

Most analysts believe we are heading towards a “2030 automotive revolution” with even higher growth rates. This revolution will be driven by the electrification of vehicles, autonomous cars, and dramatic changes in consumer behavior related to mobility and services associated with connectivity.

In light of these powerful trends, it is believed that the established automotive industry will experience a paradigm shift. Diverging markets will open opportunities for new players. While Tesla, Google, and Apple currently generate significant interest, they may be just the tip of the iceberg. 

With over a million units sold in 2017, the Electric Vehicle market is expected to grow at a CAGR of 22.3% from 2018 to 2025. Moreover, according to recent research over 90% of car innovations and new features are driven by electronics, which account for 35% to 40% of an average car’s production cost. 

More electronics parts mean new challenges for auto-part manufacturers and car makers, who must adhere to the strict quality standards of the automotive industry. For example, the number of Electronics Control Units (ECUs) is growing and manufacturers are looking for effective solutions to inspect them in order to detect and prevent typical and critical defects, such as those in ports and connectors.

Automated visual inspection can be used to identify defects in critical EV components, promoting quality and simplifying traceability.

Kitov-CorePlus has a proven track record at finding defects that are critical for automotive manufacturers: ranging from new electronics defects, such as bent pins on connectors and ports, to “old fashioned” surface defects, such as scratches and cracks on metal parts, coverage defects typical to paint and galvanized surfaces, as well as missing components of complex assemblies and sub-assemblies.

Facing bold competition and unpredictable consumer behavior, leading automotive manufacturers require a cutting edge and flexible production environment. Industry 4.0 initiatives are also taking place in the automotive industry, despite its already high level of manufacturing automation. Manufacturers are striving for better and smarter production environments, and seek new ways to boost their quality and flexibility while reducing operational costs.

Automating the visual inspection process is one of the most desired areas for improvement. With automated visual inspection, process manufacturers can for the first time ensure that they find all critical defects on the production floor. They can also use big data analytics to discover and eliminate the root causes for defects and strive towards 0 dppm.

Quality costs are significant for auto makers and their supply chain. Automation gives them an opportunity to save labor costs and to move line workers to tasks with higher and more promising ROI. In most markets today skilled employees are a scarce resource, further enhancing the value of automation. Thus, a fully automated smart visual inspection solution, such as Kitov-CorePlus, that learns and improves over time and adjusts to the manufacturing environment is a true competitive advantage. 

By using a flexible and digitally transformed visual inspection process, automotive manufacturers will be able to introduce new products and new models in a rapid and competitive manner. Moreover, leveraging a true digital inspection solution can support leading manufacturers in their quest towards mass customization, allowing them to manufacture personalized vehicles that meet the particular demands of consumers.