Case Studies: #RAS-001
Rassini Case
Leading Tier 1 auto supplier utilized data from i-5O’s vision system to manage bottlenecks, through process validation and instant alerts on the production floor
Overview
Rassini
Rassini is the world’s largest producer of suspension components for light commercial vehicles and the only fully integrated brake rotor producer in America. The company develops mobility solutions through big data, artificial intelligence, widespread digitalization, and innovation in both processes and materials. Headquartered in Mexico, Rassini offers solutions to car manufacturers in 10 countries, supplying components to more than eight million cars each year. i-5O Computer Vision System is deployed in their manufacturing facility in Flint Michigan, USA, where brake systems and components are manufactured. The video data generated by i-5O’s technology has helped the team at Rassini with process validation and labor optimization.
Problem
Rassini experienced labor shortages resulting in prolonged bottlenecks and extended production delays, due to a lack of visibility into operations resulting in an inability to identify and resolve production issues in a timely manner
Since Covid-19, Rassinie has faced a shortage of experienced labor, with the required skills and knowledge to manage plant operations smoothly. In case of a bottleneck or machine breakdown, it would take a while for the issue to be identified and subsequently resolved, leading to an increase in production downtime. Additionally, due to lack of workforce planning and optimization, there were too many operators on certain larger stations, sitting idle, while production issues on other stations were being overlooked. This resulted in lower efficiency and increased idle time
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Solution
Implementation of i-5O computer vision system to uncover inefficiencies through enhanced visibility and direct instant notifications for quick resolution of bottlenecks
i-5O computer vision was deployed to monitor operations effectively. Through the installation of cameras and the AI vision system, Rassini gained unprecedented insight into their operations. Machine breakdowns and other potential bottlenecks were instantly detected and direct notifications would be sent to the plant supervisor in real-time, speeding up the resolution process significantly. This allowed Rassini to eliminate production delays, ensuring smooth workflow and on-time delivery. Additionally, i-5O provided them with real-time video analytics to study anomalies. Through continuous monitoring of manual operations, processes were strengthened, reducing the use of faulty parts and manual errors on the production line.
Our Results
18% increase in productivity from alerts
Smooth workflow and on-time delivery
Significant reduction in manual errors
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