Case Study: Large Automotive Manufacturer achieves improved part quality and reduced warranty costs with eFlex Systems

Large Automotive Manufacturer Integrates eFlex Vision with Cognex Cameras to Optimize Vision Inspection System, Improve Part Quality and Reduce Warranty Costs

Large Automotive Manufacturer—a global automaker with a 2 million sq. ft. transmission plant and a $323M investment in a new 6-speed assembly line—faced high warranty exposure and quality risk from manual inspection and a fragmented image-storage approach (50 PCs, lost images, no diagnostics). To unify inspection image management and improve part-level traceability, the manufacturer turned to eFlex Systems and its eFlex Vision software, integrated with Cognex In-Sight and DataMan cameras.

eFlex Systems implemented eFlex Vision with more than 300 Cognex cameras, a Dell EqualLogic server (71 TB net), and standardized file naming to centrally process roughly 200,000 images per day (~200 images/minute) with a system capacity up to 1,500 images/min. The solution delivered real-time monitoring, alarms for missing images or degrading cameras, 12-month image retention, faster root-cause and warranty determinations, fewer false rejects, elimination of challenge-part runs, and removal of scattered PC maintenance—saving time and reducing warranty and operational costs. eFlex Systems’ integrated platform enabled engineers to search and export images plant-wide from a single web interface, dramatically improving inspection reliability and response.