$700 million in recall and rework costs affecting 2 million vehicles caused by process deviations and manual errors going undetected on the production floor

Auto manufacturing and assembly involve plenty of manual processes prone to human errors, posing a high recall risk if unnoticed. It was identified that most manual errors occurred due to misalignment of panels, inaccurate fastening of bolts and imprecise placement of clips on vehicles. Most of these errors would only be noticed with real-time monitoring, leading to an increased risk of recalls. Others were usually identified late in the process, requiring disassembly, rework or even scrapping the entire unit, leading to wastage of materials, labor and time. Operator-driven assembly errors were therefore adding to costs massively regarding frequent rework on the production line and vehicle recalls.