Case Study: automotive manufacturer achieves real-time weld quality assessment with Falkonry

How Falkonry Enabled Real Time Quality Assessment

The automotive manufacturer faced a challenge with the variable quality of its machine welds. Visually inspecting each weld was impossible and ineffective, leading to high inspection costs, unnecessary rework, and potential warranty issues from defective welds making it into finished vehicles. To address this, they partnered with Falkonry and implemented its Operational AI software.

Falkonry's solution utilized real-time machine data, including current, voltage, and wire speed, to build models that classify welds. This enabled the customer to accurately assess weld quality automatically. The results were significant: Falkonry helped reduce the number of welds sent for manual visual inspection by 96% and could analyze over 60,000 welds in under two minutes, greatly improving quality management.