Background
As a global Tier 1 supplier of automotive electronics, our customer is renowned for innovation and operational excellence, operating over 20 manufacturing plants worldwide. This project involved the assembly and testing of a complex electronic module designed for use across multiple vehicle platforms. To meet their high annual production targets, the customer required a production line capable of handling aggressive cycle times while integrating advanced vision-based inspections to ensure only compliant modules entered the supply chain.
The increasing complexity of automotive electronics demanded more rigorous and reliable in-process checks. However, the customer’s existing vision systems were fragmented, lacked integration, and were difficult to adjust, leading to inefficiencies and challenges in scaling operations to meet production demands.
Solution
ALPHR implemented a fully integrated vision inspection system designed to overcome these challenges and enhance the customer’s production line. The system combined advanced vision hardware and technologies to ensure precision and efficiency at every stage of inspection.
Key Technologies Deployed:
- Vision Sensors for part presence checks and Optical Character Recognition (OCR) to verify correct component placement and identification.
- Vision Cameras for OCR, colour recognition, and code reading, ensuring accurate labelling and part identification.
- 3D Scanners for inspecting electrical connector pin height and alignment, as well as thermal paste and adhesive placement, ensuring functionality and module integrity.
Our integration process began with rigorous pre-implementation trials on prototype assemblies. These trials allowed us to fine-tune inspection protocols and ensure a seamless transition to full production. With minor adjustments made during the implementation phase, the system was fully operational with minimal disruption to the customer’s schedule.
Through close collaboration with a leading vision hardware manufacturer and leveraging our extensive expertise, ALPHR optimised the system for precision, repeatability, and long-term reliability, making it an ideal fit for the customer’s high-volume production needs.
Results
The advanced vision inspection system transformed the customer’s manufacturing capabilities, delivering a range of operational and performance improvements.
Setup times were significantly reduced thanks to the pre-defined hardware configurations and streamlined integration process. The fully integrated system also allowed for remote adjustments to vision programs, enhancing flexibility and minimising downtime during production changes. This marked a substantial improvement over the customer’s legacy systems, which lacked these capabilities.
By improving the accuracy and consistency of inspections, the system minimised defects and ensured only fully compliant modules progressed to the supply chain. This reduced the risk of faulty products, enhanced quality control, and reinforced the customer’s reputation for excellence in the automotive electronics sector.
With greater confidence in the reliability of their production line, the customer was able to meet aggressive production targets and scale operations efficiently. The solution not only addressed their immediate challenges but also positioned them for sustained success in a competitive and rapidly evolving industry.
By integrating ALPHR’s advanced vision inspection system, the customer achieved a robust, future-ready production process that supports high-volume manufacturing while maintaining impeccable quality standards.
