A LEADER IN AI THAT ENABLES AUTONOMOUS MANUFACTURING
Case Study: Stud Weld Quality in Automotive Assembly Lines
Our client is a major luxury and utility vehicle manufacturer that pride themselves on the quality,
safety, and reliability of their vehicles. The company operates a high-capacity automotive assembly
plant in South Africa, where its manufacturing activities contribute significantly to job creation and the local economy.
THE CHALLENGE
Within our client’s manufacturing process, the body shop is one of the most complex areas, with at least 200 robots in operation. It is within this area that they were experiencing some challenges in their stud welding operations—with plant-wide implications. The main problem was the significant increase in downtime due to stud welding faults, resulting in substantial costs to the business.
Due to the inherent complexity of the stud welding process, traditional statistical solutions fall short in trying to address the problem. Since our client prides themselves on maintaining premium quality in their completed vehicles, they decided to approach DataProphet to help find a durable solution to the problem.
THE SOLUTION
We sent a dedicated team of data science experts to the facility. After an initial data collection phase, we implemented DataProphet PRESCRIBE, our AI-enabled process parameter optimization solution, at their facility.
Because no two manufacturing facilities are alike, DataProphet PRESCRIBE took into account the uniqueness of our client’s production facility, seamlessly integrating with their existing data and IT infrastructure. A dynamic control plan would be produced with recommendations for the optimal setpoints and control limits for each welding parameter.
IDENTIFICATION OF WELD TYPES
DataProphet PRESCRIBE was able to identify over 800 stud types used in the facility’s welding operations—describing optimal process parameter values for all 800 stud types simultaneously.
INCREASED WELD TIME
Due to the complex interactions underlying our client’s stud welding process, a vast number of process parameters influence the quality of their welds, including weld time and current. DataProphet PRESCRIBE captures these complex interactions in our client’s processes — consistently predicting weld quality.
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WHY CHOOSE DATAPROPHET AS YOUR AI PARTNER
Too often, AI-as-a-Service providers equate research-based methodologies with one-size-fits-all industry solutions. DataProphet works closely with partners to gain an understanding of their unique set of production problems. We adopt AI-driven manufacturing solutions to the production dynamics of your factory floor, incorporating our proven, industrial process expertise, but taking our cues from contextualized feedback. We understand that most impact is achieved by building machine-learning models to mesh with your production lines' realities and the assets that drive them. Our partnerships are guaranteed win-win.
Production Increase
Product Traceability
0% External Scrap
Guaranteed ROI
SOME OF OUR CLIENTS LEADING THE PACK
Our client successes include eliminating external automotive scrap, reducing mechanical welding defects by 75%, and halving the cost of non-quality – all within six months of implementation. Get results fast.
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