Reduce defects and downtime with AI-enabled automated inspection

A large multinational automobile manufacturer that produces millions of vehicles each year collaborated with IBM to streamline its manufacturing process with seamless, automated inspection powered by real-time data and artificial intelligence (AI).

As an automobile manufacturer, we have a unique obligation to deliver high-quality products to our customers. Ideally, defects should be discovered and corrected well before the car is delivered to the consumer. These defects are costly, often difficult to identify, and pose numerous serious risks to customer satisfaction.

Quality control and early defect detection are paramount to delivering vehicles that meet or exceed customer expectations while maintaining standards, improving operational efficiency, reducing costs and protecting the manufacturer’s reputation.

How IBM helps customers better detect and correct defects in manufacturing

IBM worked with our clients’ technical experts to deploy IBM® Inspection Suite solutions to reduce defects and downtime while enabling faster action and problem resolution. Deployed solutions include fixed-mounted inspection (IBM® Maximo® Visual Inspection Mobile) and portable inspection (IBM® Inspector Portable). In situations where a head-mounted display is required, a hands-free wearable inspection (IBM® Inspector Wearable) is also available.

Although computer vision for quality has existed in a more primitive state for the past 30 years, the lightweight and portable nature of IBM’s solution, based on the standard iPhone and using readily available hardware, really caught the attention of customers. The client liked the fact that employees could use the solution anytime, anywhere, even while objects were moving.

Scale inspections to 30 million for immediate and significant defect reduction

IBM Inspection Suite improved our customers’ quality inspection processes without coding. The client found the system simple to train and deploy without the need for a data scientist. The system learned quickly from images of acceptable and defective work products, enabling the solution to be up and running within a few weeks. Implementation costs were also lower than viable alternatives.

The ability to deliver AI-driven automation using intuitive processes in the factory allowed this customer to quickly scale this user-friendly technology to numerous other facilities, supporting more than 30 million inspections. The customer realized measurable success almost immediately, with a significant reduction in defects.

Customers, as voted on by technology community leaders, have given IBM their annual IT Innovation Award for the technologies they believe have delivered the innovations that create the most value for the company. In presenting the award, the client’s executives declared that discussions with IBM on innovation led to a focus on improving manufacturing quality through AI automation.

Inspection Suite supported our customers’ quality initiatives through field process control and quality improvement at the point of assembly or installation. Additionally, the solution provided continuous process improvements that helped customers lower repair and warranty costs while increasing customer satisfaction.

Transparency and Trust in AI

IBM Inspection Suite helped clients deliver higher quality vehicles to their customers by leveraging IBM’s deep AI capabilities that can be deployed on a cost-effective edge infrastructure across the client’s plants. Customers are now expanding to additional plants and use cases thanks to collaboration and innovation with IBM.

All members of the IBM team were honored that this client recognized IBM’s business and technology achievements. We believe this recognition reflects IBM’s values ​​of significant customer commitment and innovation. This is a direct recognition of the value that IBM Inspection Suite brings to our customers.

IBM’s mission is to leverage the power of data and AI to deliver real-time, predictive business insights that help our clients make informed decisions.

Empower your subject matter experts with automated visual inspection