Implementing AI for real-time defect detection
About Sansera
The Swedish company Sansera, which is a manufacturer of connecting rods for diesel engines, was founded in 1973 as an offshoot of Volvo in Skövde. For four years now, Sansera has had Indian owners. Sansera has 15 factories in India and one in Trollhättan. 7,000 employees are part of the group, of which 70 work in Trollhättan, where production runs around the clock, except for a stop on Thursdays for maintenance.
\ Challenge
Ensure highest quality standard for 700 000 rods a year
700,000 connecting rods are manufactured every year at Sansera. Each connecting rod is manually checked and lifted before leaving the factory. There are 18 different error types and the check takes between 15 and 20 seconds for the employee. Each connecting rod weighs around 5 kg so there will be many lifts in one shift.
The connecting rods are then used in buses, trucks and ships where every step of the manufacturing process must be of the highest quality, consistent, reliable and documented. Since 4 years ago, there is a new factory in Trollhättan where they have already started to automate several processes in the manufacturing. With the help of AI, you can improve parts of the manufacturing process, reduce strain injuries and improve the working environment for employees.
The AI model uses an automated, deep learning defect detection system in the production process using computer vision and sensors.
By implementing quality control and quality assurance methodology in manufacturing processes, it is ensured that the end products meet the customers' requirements and satisfaction and catch any errors early in the process. The project is ongoing and developing all the time. The next step with the customer is to look at other areas of manufacturing that can also use the technology.
\ Result
Reduced cost from a 1 million to 20 000 SEK
By teaching a computer what the errors are, via artificial intelligence, Sansera can have a simpler equipment for around 20,000 SEK instead of a million.The computer has learned to look for and find errors and sort them out immediately. The result is that there are fewer errors for the operator to review and that the robot does the work so that the operator does not have to do the heavy lifting. In addition, there is a traceability that did not exist before on each individual connecting rod, which has been requested by end customers. This saves time and money.
- Traceability
- Saves time and money
- Reduces the number of defective parts in the production process
Sansera Sweden manufactures connecting rods for diesel engines for a range of vehicles and industrial applications
Sansera Sweden manufactures connecting rods for diesel engines used in buses, boats, trucks but also a range of industrial applications such as generators and compressors. We aim to become Trollhättan's fifth largest company with a turnover of over 500 million. We call our vision Give Me 5. To achieve our vision, we have built a new factory in the Stallbacka area in Trollhättan where we have just moved our entire business.
More information about Sansera is available at:
sansera.in
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