100% Vision-Guided Inspection Line for Leading German Automotive OEM

Client

Major German Automotive Tier-1 Supplier (confidential – global leader in powertrain and chassis components)

Industry

Automotive & Auto Components

The Challenge

The client’s existing manual and semi-automated inspection process for critical engine and transmission components was creating high scrap rates, inconsistent quality, and a bottleneck that limited line speed to 18 seconds per part. Zero-defect requirements from their German OEM customers demanded 100% inspection, but manual methods could not deliver this at production volumes without excessive labour and cost.

Invensys Solution

Invensys Engineers designed, manufactured, and commissioned a fully automated 100% Vision Inspection Line. The system integrates high-resolution multi-camera vision, AI-powered defect detection, and servo-driven part handling into a compact 8-station rotary cell that seamlessly integrates with the client’s existing production line.

Key Technical Features

8 high-speed industrial cameras with telecentric lenses and custom LED lighting
AI vision model (trained on 50,000+ real parts) for surface, dimensional, and assembly defects
Servo-controlled rotary indexing table with ±0.01 mm repeatability
Real-time reject handling with automated sortation and traceability logging
Industry 4.0 integration (OPC-UA + MES data push)
CE-marked for European deployment

Measurable Results

Zero escapes to customer (100% inspection achieved)
42% faster inspectioncycle (18 s → 10.5 s per part)
68% reduction in labour requirement
Scrap rate reduced by 91%
ROI achieved in under 7 months

Products & Systems Delivered

Special Purpose Machine (SPM) – 100% Vision Inspection & Sorting Cell

Proven Results. Trusted by Global Automotive Leaders.

Client Voice

The Invensys vision system has completely transformed our quality process. We now run at full takt time with zero defects reaching our OEM customer. Their engineering precision and rapid commissioning were outstanding.