About the Customer
A premier manufacturer of high-precision engineered and forged components for the automotive and industrial sectors. The company’s extensive portfolio relies on rigorous, real-time quality verification to ensure flawless consistency and seamless dispatch clearance.
Challenges & Opportunities
The client sought to modernize visual inspections for their forged components to accelerate throughput, boost productivity, and improve dispatch readiness. With manual checks taking 15–20 minutes per part, automating the workflow offered key opportunities to:
- Accelerate processing: Speed up inspections and expedite Dispatch Advice (DA) issuance.
- Eliminate redundancy: Reduce repetitive quality checks and manual data entry.
- Enhance traceability: Strengthen end-to-end tracking for rejections and rework.
- Drive accountability: Improve data accuracy for client reporting and quality audits.
Our Approach
TVS Next deployed an AI-powered Visual Quality Inspection solution to automate component tracking and digitize end-to-end quality management.
- AI-Driven Inspection: Fast-tracks validation of forged components against predefined quality metrics.
- Digital Quality Traceability: Structures inspection data with real-time access to rejection and rework history.
- Workflow & Productivity Visibility: Triggers automated escalations for pending issues and monitors progress through final Dispatch Advice (DA) completion.
- Scalable Management: Streamlines deployment using reusable templates, part-specific variables, and strict version control.
Results & Business Impact
The AI solution successfully eliminated cycle bottlenecks to optimize resource utilization, accelerate quality clearance, and fast-track dispatch workflows.
~3 Minutes
Avg AI inspection time per component
~93–95%
Calculated inspection time reduction
Up to 15–20×
Increase in theoretical inspection capacity
*Capacity and percentage figures are calculated based on baseline manual inspection times, assuming inspection is the sole limiting factor.
The Business Value
Replacing time-consuming manual checks with fast, digital quality processes to maximize workforce productivity, operational oversight, and dispatch readiness.
