Bajaj Auto’s Implementation of the SwitchOn DeepInspect® System

Introduction

Bajaj Auto faced a challenge with manual sealant inspection in crankcases, leading to errors and inefficiencies. Issues like missing or uneven sealant resulted in oil leaks, reduced engine performance, and potential engine damage. This highlighted the urgent need for an automotive vision inspection system.

DeepInspect®- AI Powered Sealant Inspection Software

DeepInspect is an AI powered automotive  quality inspection software that helps manufacturers like Bajaj automate their quality process. Bajaj Auto has taken a big step forward by implementing the SwitchOn DeepInspect® system, which automated crankcase sealant inspection across all SKUs on their production line. The setup includes:

• DeepInspect Software

• Industrial Camera

• Industrial Lighting

• PLC

• Industrial Controller with i5 and  GPU

The software needed fewer than 200 good sealant images and just 45 minutes for model training and validation. The entire process, from capturing the image to displaying the inspection results, is completed in less than one second, dramatically improving the speed and accuracy of their production line. 

Vision AI in Crankcase Sealant Inspection- How it works?

The process begins with an operator manually placing the crankcase onto an automatic fixture.  The fixture rotates 180 degrees. A robot then applies sealant to the crankcase.The fixture then returns to its original position, where the The DeepInspect system inspects sealant for presence, continuity, and thickness.

Why DeepInspect for automated sealant inspection?

The implementation of the SwitchOn DeepInspect® system has transformed Bajaj Auto’s inspection process. The system not only eliminated the need for manual labor but also significantly enhanced efficiency and reduced human error. With an impressive accuracy rate of 99.5%, Bajaj ensures that only high-quality products reach the market. 

• Successfully carried out sealant inspection for thickness, continuity, sealant presence/absence

• The  false  positive rate was minimized to  just  4%,  ensuring   that   almost  all  good sealants were accurately  identified and correctly classified.

• Boosted vehicle performance and effectively  eliminated  engine oil  contamination and prevented potential leakages.

Conclusion

By integrating the SwitchOn DeepInspect® system, Bajaj Auto has taken a significant step forward in ensuring excellence in manufacturing. The result is a highly efficient, automated inspection process that upholds the company's commitment to quality, innovation, and customer satisfaction.