In the automotive industry, quality and safety standards are non-negotiable. Every vehicle that rolls off a production line must not only meet customer expectations but also ensure the safety of its occupants. To achieve this, each component undergoes multiple inspections throughout the manufacturing process.
However, end-of-line inspections stand out as the most critical. Why? Because they validate key aspects that directly impact customer perception and vehicle functionality—commonly referred to as “fit and finish”:
1. Gap and flush measurement, crucial for ensuring uniformity in joint alignment, which affects both sealing and aerodynamics.
2. Validation of exterior components*, such as logos, badges, mouldings, or trims, to ensure compliance with design specifications.
3. Inspection of surface defects, including dents and scratches, which can affect appearance and customer satisfaction.
Traditionally, these inspections were carried out manually, but the limitations of human inspection have driven OEMs to seek automated solutions offering precision, repeatability, and efficiency. This marked the beginning of the All-in-One system’s journey, pioneered by EINES in collaboration with a forward-thinking client.
Automating Inspections: Why Make the Change?
Years ago, all automotive inspections were performed manually. What were the limitations? As we know, operators, relying on their experience and skill, often delivered acceptable results. However, these outcomes were heavily influenced by human perception and physical condition. Subjectivity, fatigue, and human error were persistent challenges.
With the advent of the 3rd Industrial Revolution—characterized by the integration of electronics, computing, and automated production—a critical question emerged: Could manual inspections remain viable in an increasingly automated environment? OEMs quickly realized they could not. Precision, consistency, and digital data were needed to guarantee quality at every production stage.
A major OEM entrusted EINES to lead a transformational change in this context. This collaboration not only revolutionized inspection processes but also laid the foundation for the All-in-One system we know today.
From Manual Inspection to Robotic Automation: The Definitive Solution?
The first major challenge was automating gap and flush measurement. For decades, this task had been performed manually by operators using gauges or even by touch—rudimentary, subjective, and physically demanding methods.
In 2004, two robotic cells were installed with laser technology to automate in-line gap and flush measurement. This represented a significant leap from manual methods, leading to an important realisation: Why stop at one type of inspection? If robots could automate measurements, couldn’t they also handle part-to-spec validation?
EINES did it again. In 2005 installed a robotic cell equipped with basic vision technology for part-to-spec validation. Thanks to EINES’ Multi Error Proofing (eMEP) technology, this robotic cell could verify exterior components, enabling OEMs to achieve unprecedented precision in this critical stage.
However, despite being more effective than human inspection, both robotic systems had significant drawbacks: high energy consumption, risk of collisions with vehicles, excessive space requirements, and limited inspection capabilities.
This led the OEM to ask: Could a more efficient, compact, and versatile solution exist?
The Emergence of the Metrology Tunnel: A Revolutionary Solution?
Inspired by the success of the paint defect detection tunnel (ESFI) launched in 2014, EINES engineers took on the challenge of developing a contactless metrology station that did not require robots or other moving mechanisms, making it safe and eliminating the need to project any laser or be near the vehicle to take measurements.
After extensive research and testing, the first metrology tunnel (EIFIS) was installed in 2019 at a customer’s facility, just before the robotic cell performing the same task. This allowed for a direct comparison of the robotic cell versus the tunnel.
The result? An overwhelming success! A second tunnel was implemented within months, allowing the robotic cells to be dismantled entirely. The metrology tunnel eliminated safety risks, reduced energy consumption, and freed up valuable floor space. Most importantly, it exceeded client expectations by delivering more precise and consistent sections measured in a compact, efficient system.
Integration of Functionalities: Why Not Combine Everything?
With the metrology tunnel already capturing images of every vehicle part, EINES saw an opportunity: Why not use these images for part-to-spec validation?
EINES proposed integrating eMEP technology into the metrology tunnel to perform part-to-spec validation, eliminating another robotic station from the line along with its associated drawbacks.
By summer 2021, the metrology tunnels were updated to include eMEP technology. This resulted in a unified system capable of conducting two critical inspections simultaneously. By early 2022, robotic cells were dismantled, marking another milestone in inspection process optimization.
Surface Defect Inspection: The Final Challenge?
The last remaining human inspection was for surface damage, such as scratches and dents, caused during the final assembly stages. While seemingly minor, these defects significantly impact customer perception and can lead to future issues like body corrosion.
In early 2022, EINES began developing a solution to automate this task. By summer, we installed an experimental “add-on tunnel” next to the metrology tunnel, featuring two hardware setups: a semi-arc with zebra lighting and cameras and another semi-arc with specular lighting and a different camera type. Of course, this “add-on” tunnel was powered by AI, another challenge to face.
After rigorous model training, data collection, and client feedback, the perfect solution was achieved, tailored to the OEM’s needs and quality standards.
The All-in-One System: A Destination or a New Beginning?
The metrology tunnel’s success led to the creation of the All-in-One system, which combined three inspections: gap and flush measurement, Part-to-spec validation, and Surface defect detection. This breakthrough not only optimized in-plant processes but also ushered in a new era of quality automation.
Continuous Innovation: What’s Next for EINES?
At EINES, innovation never stops. Our R&D team constantly works to improve existing systems and develop new solutions to anticipate OEM needs. Ultimately, there’s always another question to answer, another process to optimize, and another standard to surpass.
Our greatest allies are our clients, who provide opportunities for joint development, yielding mutual benefits and endless possibilities. The market’s demands and needs speak for themselves—and at EINES, we’re ready to listen.