5 Challenges in Automotive Manufacturing

Every automotive – from the kid’s bikes to massive cranes, is a product of an intriguing yet complex automotive manufacturing process so the automotive manufacturers know the importance of a seamless manufacturing process to deliver good quality and safe automobiles.  

However, the manufacturers face a lot of challenges in manufacturing automobiles; we have listed some of them below: 

1 Quality Assurance 

Automotives are manufactured in volumes. For instance, a truck or a road roller is a massive product with multiple components. Checking every component for its quality is a taxing process; if the components are not inspected thoroughly, it will affect the quality of the automotive; which could impact the safety of the vehicle as well. Quality assurance for every automotive is certainly a major hurdle for automotive manufacturers. 

2 Employee safety 

In an automotive manufacturing facility, labourers are involved in lifting, moving, or carrying machines and heavy equipment; it is not only laborious but also puts their safety at risk as they work with hazardous automotive components. Automotive manufacturers often find it challenging to manufacture heavy machines and equipment for automotive whilst considering the safety of their employees. 

3 Shortage of skilled labour

The availability of labourers is humongous, but how many out them have the skills to improve manufacturing efficiency? Not many.  Lincode Labs catered to a well-known automotive manufacturer to address a similar problem; the manufacturer incurred a huge loss because of export of false parts in CKD (complete knocked down kit) as the labourers were unskilled to identify the right parts. They mistook the wrong parts for the right ones for the fact that the parts looked identical with a very minor variation in their appearance.

4 Innovation and novelty 

To achieve a competitive advantage, it is important to bring innovation and novelty to the product. However, since automotive manufacturing is a complex process; the manufacturers are mostly involved in ensuring that the whole process is smooth and error-free, leaving very little time to think about innovation. 

5 Longer cycle time

Automotive manufacturing has longer cycle time as compared to other industries. Multiple components have to be produced, assembled, and inspected at every production stage. Automotive manufacturers have the added pressure of delivering the product at the right time despite the longer cycle time. 

While the challenges in automotive manufacturing are inevitable; it should not necessarily impact the manufacturing process, especially in this digital age where manufacturers can scale up the automotive manufacturing process with relevant technologies like Artificial Intelligence (AI). 

Benefits of AI in Automotive Manufacturing 

AI for quality assurance 

As compared to the traditional machine vision that detects defects using only a golden template at a fixed image orientation, AI-backed computer vision technology captures microscopic defects, irrespective of the image orientation. For instance, the traditional machine will miss out on a black mark on a black surface (black-on-black) but AI vision is capable to capture this exception seamlessly; such capabilities are extremely crucial for quality assurance. 

AI ensures human safety

AI not only sends alerts about a possible danger the labour may be exposed to while he works with heavy, hazardous equipment, it also eliminates the need for humans to work with such equipment. The process of moving, lifting, and inspecting heavy automotive equipment is automated; making it much safer and efficient. 

AI helps in innovation 

AI’s Generative Design capability significantly helps in innovation. With basic inputs like height, weight, width, size, etc. the manufacturer will have plenty of ideas to innovate to the manufacturing process that delivers good quality, innovative and safe automotive. 

AI reduces cycle time 

AI vision system monitors every stage of the production cycle, automates the most complex manufacturing processes, and predicts defects and errors in the assembly line beforehand. AI helps in reducing cycle time, increases production capacity, and improves the delivery rate. 

Choose Lincode’s AI Vision System

Lincode’s AI Visual Inspection System is a state-of-the-art, Industry 4.0 solution that enables manufacturers to identify surface defects, identify and measure individual components, and generate real-time data about products on the production line. With AI and deep learning, we can significantly reduce false-positives and false-negatives generated by traditional machine vision and capture untrained defects.

Reach out to us at sales@lincode.us to know more about our solution.

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