Case Study

GRID HMI: Visual Inspection

Previous solution

Visual inprection Solution
  • Error-prone
  • Subjective
  • Many cameras
  • Expensive
  • No MES connectivity
  • Complex

A leading automotive manufacturer operates one of the largest and most complex assembly plants in North America. In an attempt to improve inspection efficiency and reduce costly errors associated with paper-based verification, the company considered using a multi-camera computer vision system to identify features on assembly line vehicles. A line manager would use the images to verify vehicle requirements against a paper checklist. The solution offered some increase in speed, but the cost, complexity, subjectivity and lack of MES connection would likely increase error rates and overall inefficiency.


Visual inprection GRID HMI
  • Error-proof
  • Objective
  • One camera
  • Cost-effective
  • MES connectivity
  • Simplified

Using the GRID HMI, the VIN of each vehicle passes directly to the MES system, which responds with the feature requirements to be captured by the computer vision system (CVS). The GRID HMI integrates the line’s PLC and a single-camera CV station to coordinate when pictures should be taken, as particular features come into frame. The device displays the inspection results and informs the line manager if the vehicle has passed or failed. This removes operator subjectivity from the process while integrating previously unreachable assembly nodes.