Automotive Parts Inspection
One of the world’s largest automotive parts manufacturers replaced manual inspection with Intelgic’s AI-powered vision system. Using robotic motion, specialized lighting, and advanced defect detection, every surface of complex parts is now inspected automatically.
- Faster cycle times
- Zero defects passed
- Consistent quality
- Digital reports & analytics
Intelgic is driving Zero Defect Manufacturing in the automotive industry.
The Challenge
One of the world’s largest automotive parts manufacturers faced a recurring challenge in their quality control process. Their production line produced a wide range of complex-shaped parts, but the inspection process relied heavily on human operators.
This manual approach had major drawbacks:
- Inconsistency – different operators often judged defects differently.
- Slow inspection cycle –manual checks could not keep up with production speed.
- Lack of digital records – no systematic way to capture and store inspection data.
As demand grew, it became clear that manual inspection was no longer sustainable. The company needed an automated, accurate, and traceable system that could ensure zero-defect quality while improving efficiency.
The Intelgic Solution
Intelgic engineered a custom Automated Optical Inspection (AOI) system specifically designed for the client’s complex automotive parts.
Key Components of the Solution:
- Machine Vision Cameras & Lenses – High-resolution imaging devices capable of capturing minute defects across varied surfaces.
- Specialized Lighting – Customized illumination setups to handle reflective, curved, and uneven surfaces of automotive components.
- Robotic Motion System – Multi-axis robotic rails that moved cameras and lights across different regions of the part, ensuring 360° coverage.
- Intelgic’s Live Vision AI Software – Real-time image processing and AI-based defect detection engine, integrated with reporting and analytics.
How It Works
- The robotic motion system positions the camera and lighting to capture all surfaces of the part.
- High-resolution images are processed instantly by Intelgic’s software.
- Defects are automatically detected, classified, and recorded.
- The system generates a comprehensive inspection report, complete with defect details and pass/fail status.
The Outcome
The transition from manual to automated inspection delivered measurable results:
- Inspection Cycle Time Reduced –
Faster imaging and processing kept pace with high-volume production.
- Zero Defect Assurance – No defective part passed through undetected.
- Consistency Achieved – Automated detection eliminated human subjectivity.
- Digital Reporting – Each inspection generated detailed reports and analytics, enabling traceability and process improvement.
The Impact
By deploying Intelgic’s automated inspection system, the automotive manufacturer:
- Strengthened its quality assurance process.
- Reduced warranty risks by ensuring only defect-free parts were shipped.
- Gained valuable production insights through inspection analytics.
- Improved customer trust with consistent product quality.
This success story demonstrates how Intelgic enables the automotive industry to achieve Zero Defects Manufacturing through the integration of machine vision, robotics, and AI-driven software.
