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Case Studies: #SUZ-001

Suzuki Case

A leading global automotive manufacturer utilized i-5O’s vision system to reduce rework costs and eliminate the risk of recalls, through real-time process inspection and immediate corrective actions

Suzuki

Overview


Suzuki

Suzuki Motor Corporation, headquartered in Hamamatsu, Japan, is a globally renowned automobile and motorcycle manufacturer. Founded in 1909, Suzuki has established a legacy of innovation and quality, offering various vehicles that cater to different market needs while maintaining a strong commitment to sustainability and advanced technology.i-5O’s Computer Vision System is used in their Sagara Plant which produces compact passenger vehicles, engines and engine components. The data generated by i-5O has helped the team at Suzuki reduce recall rates through real-time process inspection.

Problem


$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.

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Solution


i-5O’s Computer Vision system was implemented as a digital poka-yoke solution to verify that manual assembly processes are performed correctly, eliminating 100% of operator-driven assembly errors to avoid rework costs and recall risks

Using live-streaming video data, i-5O vision was deployed to validate SUZUKI’s complex manufacturing and assembly processes. A real-time process validation system was implemented in which errors were caught as they occurred, and line managers were immediately notified through an instant alert system. The alert system also provided information about where the error occurred to facilitate quick resolution. This early error detection allowed for immediate corrective actions, reducing the need for costly rework and minimizing production waste, ensuring that each vehicle was assembled correctly, and eliminating recall risks.

Our Results

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Instant alerts on errors occurred

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Rework cost saved $100 Million per year

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Model Precision 98%+

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