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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
Gentherm’s existing computer vision system began producing a high volume of false positives during inspection after a full redesign of the production line, including new lighting conditions and updated tooling.
The algorithm could no longer reliably verify heating wire placement 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).
Solution
Blackthorn AI reworked image preprocessing and contour detection in Gentherm’s existing inspection system, so it recognises the heating wire reliably under the new lighting and materials. Inspection tolerances (±1.5 mm) and cycle time stayed the same, and the update shipped as a white-label release inside the existing system.
To stabilise the inspection system under the new lighting, 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
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~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
