In the automotive industry, ensuring the longevity and safety of a vehicle’s structure is of utmost importance. For a leading automotive OEM, addressing underbody rust presented a critical challenge that required an innovative solution. The Anti-Corrosion team, in collaboration with the Customer Quality Services Group, aimed to revolutionize the way underbody rust is assessed and monitored over time.
The Challenge
Traditionally, underbody rust assessment was performed manually, relying heavily on the surveyor’s interpretation. This method led to inconsistent and subjective results, with only 100 to 150 surveys conducted annually due to limited resources. The manual process was not only time-consuming but also lacked the scalability needed to effectively monitor corrosion across a vast number of vehicles.
The Solution
To tackle this challenge, the automotive OEM partnered with Ascentt to introduce a groundbreaking solution that leverages advanced computer vision technology to automate the underbody rust assessment process.
- Strategic Deployment of Underbody Scanners: Underbody scanners were installed at key dealerships, with plans to expand to five locations in the first year. This allowed every vehicle coming in for service to be scanned, seamlessly integrating rust assessment into the existing service workflow.
- Automated Rust Segmentation and Ranking: A fully automated process was developed for rust segmentation and ranking, utilizing batch-mode inferencing to process large volumes of image data efficiently. This eliminated the inconsistencies of manual assessments.
- Custom-Built User Interface: Engineers and technicians were provided with a custom-built user interface to analyze underbody rust scans with precision and consistency. This tool enhanced collaboration and streamlined the decision-making process.
The Results
The implementation of this innovative solution led to transformative results:
- Significant Increase in Data Collection: In the first year alone, approximately 10,000 vehicle surveys were collected and analyzed—far exceeding the previous manual efforts.
- Standardized Rust Ranking System: A uniform rust ranking system was introduced across five levels and three body frames, ensuring consistency in assessment and reporting.
- Enhanced Accuracy and Efficiency: The automated process improved the accuracy of rust detection and reduced the time required for assessments, allowing for proactive maintenance and better resource allocation.
- Cost Reduction and Improved Customer Satisfaction: By enhancing vehicle integrity and reducing the likelihood of corrosion-related issues, the company reduced costs associated with repairs and warranties, while also improving driving conditions for customers.
Conclusion
By embracing advanced computer vision technology, the automotive OEM transformed its underbody rust detection from a manual, inconsistent process into an automated, accurate, and scalable operation. This success story highlights the power of innovation in overcoming industry challenges and setting new standards for efficiency and safety.
Transform Your Operations with Ascentt
At Ascentt, we specialize in leveraging cutting-edge technologies like computer vision to solve complex business challenges. If you’re ready to revolutionize your operations and achieve transformative results, contact us today to discover how we can drive your success forward.