AI-Powered Sheet Metal Inspection — Field Results
Two real-world deployments. Two automotive clients. Zero compromise on accuracy.
Case Study 01: JBM Auto — Body-in-White Inspection
AI-Powered Metal Sheet Inspection System | Hole, Bolt & Perimeter Detection
Manual Inspection Bottleneck
High-volume production required consistent hole and bolt counting — impossible to maintain with human operators.
Zero Defect Tolerance
Even one missing hole or bolt reaching customer becomes costly — required 100% detection capability.
No Data Traceability
Manual inspection left no audit trail — impossible to track defects or perform root cause analysis.
Throughput Constraints
Production speed outpaced inspection capacity — needed automated system for continuous operation.
🔵 Hole Count Detection
AI model detects all circular & oval holes and validates against configured thresholds per sheet grade. Count mismatch → instant NG flag.
🔩 Bolt Count Detection
Detects and counts bolt positions per sheet. Grade-wise spec validation. Mismatch triggers instant NG classification.
📐 Perimeter Defect Detection
Side camera monitors the complete sheet perimeter for edge defects, cracks, and deformations in real time.
| Metric | Target | Achieved | Status |
|---|---|---|---|
| Detection Accuracy | ≥99% | 100% | ✓ Exceeded |
| Hole Detection | ≥95% | 100% | ✓ Exceeded |
| Bolt Detection | ≥95% | 100% | ✓ Exceeded |
| System Uptime | ≥98% | 99.7% | ✓ Exceeded |
Case Study 02: Automotive OEM — Door Panel Inspection
Automated Metal Door Defect Detection System | LHS & RHS Door Panels
Hole Detection
Missing holes detected on LHS & RHS panels by multiple camera views to achieve 100% coverage.
Wrinkle Detection
Surface wrinkles identified via AI model across all camera views with consistent thresholds.
Folding Defects
Edge fold anomalies captured primarily by Side camera in live production environment.
Crack Detection
Surface and edge cracks detected in RHS panels with high confidence scoring and classification.
📷 Machine Vision Camera
🔭 Machine Vision Lenses
💾 Processing Unit
| Defect Category | RHS Accuracy | LHS Accuracy | Combined |
|---|---|---|---|
| Hole Detection | 98.5% | 99.1% | 98.8% |
| Wrinkle Detection | 97.2% | 96.8% | 97.0% |
| Folding Defects | 95.6% | 96.4% | 96.0% |
| Crack Detection | 96.4% | 94.8% | 95.6% |
| Overall Accuracy | 97.0% | 96.8% | 98.2% |
Ready to Deploy AI Inspection at Your Facility?
These systems are proven in production. Customizable for your specific sheet metal, door, or component specifications.
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