AI Computer Vision in the Automotive Manufacturing

Shubham Darwatkar
Aug 8
2 min read

Detecting the Barely Visible in Production

In the automotive industry, quality control is everything. A single micro-defect in a weld seam, a paint bubble, or a structural component can spark recalls costing millions and more importantly, put drivers at risk.

Manual inspections, though essential, were proving too slow and too inconsistent. That’s why leading automakers are adopting Eaglai Detect and transforming production processes with AI in Automotive Manufacturing.

Workers assemble machinery in a spacious, well-lit factory with car frames overhead. Siasun equipment and signs with codes C03R, C04R visible. — Defect Detection in Automotive Industry

The Challenge in the FMCG Automotive Industry

One global manufacturer faced:

Manual bottlenecks slowing down assembly lines
Micro-defects in welds, paint, and interior finish going undetected
Annual quality control costs around $25 million
Recalls averaging $10 million per incident, with 3–4 incidents per year

Implementing AI in Automotive Manufacturing: Eaglai Detect

Senquire deployed Eaglai Detect for surface defect inspection across key production stages.

The system included:

5MP industrial cameras with 360° lenses
Deep learning defect detection models trained to catch:
- Rust, cracks, dents, and blowholes
- Paint bubbles and scratches
- Misaligned parts and chamfer issues
Edge AI processors enabling real-time inspection at cycle times of 150–200 parts per minute
Automated rejection systems integrated with pneumatic ejectors

Industrial camera capturing metal components on a conveyor, with blue machinery in the background. The lens shows detailed markings.

How It Worked | Operational Flow of the AI System

Each part scanned and analyzed in real time
Defects automatically flagged and removed
AI models continuously improved via feedback loops and synthetic defect training

The Results

The impact was clear:

Detection accuracy improved to ~98% (from ~80%)
Inspection time dropped from ~45 seconds to ~12 seconds per unit
QC costs reduced by ~$10 million annually
Recall incidents cut nearly in half
ROI achieved within 18 months

The Takeaway

For the automotive industry, real-time AI vision is no longer optional. It’s the key to safer vehicles, stronger compliance, and brand protection in an increasingly competitive market.