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Industrial Computer Vision Quality Control System
Stabilizing quality control after a production and lighting redesign in automotive manufacturing
Reduction of pseudo-errors after lighting and process change
Stable heating wire position verification tolerance
Automated OK / NOK decision with machine blocking
After a full redesign of the production line – including new lighting conditions and updated tooling – Gentherm’s existing computer vision system began producing a high volume of false positives during inspection.
Pharma & Biotech
Industry
United States
Location
$200,000–$500,000
Budget
CI/CD deployment, Warehouse design, Web portal
Services
The algorithm could no longer reliably detect whether the heating wire was positioned within the allowed ±1.5 mm tolerance relative to the product contour. As a result, the system frequently blocked the machine despite correct placement, slowing down the line and reducing overall equipment efficiency (OEE).
See what we can do for youSolution
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To deliver a a fault-tolerant large-scale genome analysis platform, Blackthorn AI applied:
Project duration
01 Week
Analyzed the existing computer vision system after production and lighting redesign. Identified root causes of false positives related to illumination changes, contrast loss, and contour instability across multiple templates.
02-03 Weeks
Reworked image preprocessing and contour detection logic to ensure stable heating wire recognition under new lighting and material conditions. Improved robustness without changing inspection tolerances or production cycle time.
03-04 Weeks
Validated wire-to-contour positioning against predefined geometric tolerances (±1.5 mm). Ensured consistent behavior across all production templates and seat configurations.
05 Week
Deployed the updated algorithm to the production environment. Ran joint validation with Gentherm’s team to confirm reduction of false positives and stable real-time operation during live manufacturing.
06 Week
Implemented minor adjustments based on production feedback. Finalized the solution as a white-label update, fully integrated into the existing inspection system.
Team Size
Delivering Impact
Beyond the values already highlighted, there’s even more to discover. Our commitment to innovation, client success, and impactful results sets us apart.
Book a Meeting~1
SecReduction of pseudo-errors after lighting and process change
~1.5
MmStable heating wire position verification tolerance
100%
AutomatedOK / NOK decision with machine blocking
