How Maruti Suzuki Automated and Scaled Engine Bore Inspections with Jidoka

By deploying Jidoka’s AI-powered visual inspection systems, Maruti automated and scaled its engine bore inspection process, achieving 100% inspection coverage, over 99.5% defect detection accuracy and a 60% reduction in defect rates.

How Maruti Suzuki Automated and Scaled Engine Bore Inspections with Jidoka

Industry

Automotive OEM

Result 1

5,180 cylinder bores tested with 99.5% accuracy

Deployments

Kompass AI and Modular Vision Hardware

Result 2

60% reduction in defect rates

Overview

Maruti Suzuki, a leading automotive manufacturer, is known for its commitment to quality and innovation. With increasing production volumes and stringent quality standards, the company needed to enhance inspection processes to improve defect detection and efficiency, particularly in engine bore inspections.

Manual inspection methods were proving inefficient for maintaining high-quality standards at scale.

The Opportunity

Maruti’s manual defect detection processes were no longer efficient or fully reliable:

Over 1,000 engine bores inspected per day, requiring continuous precision and accuracy.
Operators faced challenges detect microscopic defects, surface irregularities, and assembly inconsistencies.
Sampling-based inspections left room for undetected defects, increasing the risk of performance issues and rework.
The transition to dual-bore inspections added complexity, making manual inspection impractical at scale.

Even minor defects could result in performance failures, increased warranty claims, and reputational risks. Jidoka promised exactly that - and more.

Jidoka’s AI-driven defect detection solution, Kompass, has been our partner in the collaborative journey between machines and our operators to provide a quantum leap to our quality. The data from the system enabled us to identify corrective action needed in our honing process to reduce a bore surface variation of 90 microns, which has now been reduced to 30 microns by improving the calibration and dial setting workflow.

- LINE MANAGER, PRODUCTION, MARUTI SUZUKI

Jidoka’s Approach

Jidoka installed Kompass and Modular Vision Hardware to automate and optimize Maruti’s inspection workflow:

AI-Powered Visual Inspection (KOMPASS):
Jidoka’s KOMPASS engine processed over 1,000 images per component in under 70 seconds, achieving 99.5%+ accuracy in detecting surface irregularities, scratches, and machining errors. The system performed 4,000+ inferences per minute, ensuring rapid and precise defect detection.
12-Layer Bore Imaging:
A complete 360-degree scan with 12 layers per bore enabled detailed, comprehensive defect detection, identifying even the smallest imperfections.
HILDA Framework:
The Human-in-the-Loop Designed Algorithms (HILDA) framework seamlessly integrates human expertise with automation. KOMPASS handled repetitive tasks with speed and precision, while human operators used real-time feedback to continuously train and improve AI models, enhancing system accuracy and reliabilit
.Seamless Hardware Integration: Jidoka’s Modular Vision Hardware integrated smoothly with Maruti’s existing production lines, ensuring minimal disruption.‍
Scaling for Dual-Bore Inspections: The system adapted from single-bore to dual-bore inspections, maintaining quality without disrupting workflows.‍
Advanced Analytics: Real-time dashboards provided actionable insights, enabling operators to monitor, adjust, and optimize quality metrics in real-time.

Big Wins for Maruti

By implementing Jidoka’s solutions, Maruti achieved impressive results:

100% Inspection Coverage

Achieved full component inspections, replacing sampling-based methods.

Improved Efficiency

Saved over 400 man-hours per defect by automating defect detection.

Enhanced Throughput

Increased production throughput by 20%.

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Improved Cost Savings

Reduced rework and scrap costs by 10-15% through proactive defect identification.

Tool change was identified as another root cause, for which a more thorough inspection process has been established by marking the first 10 parts after tool change for in-depth inspection. These improvements would not have been possible without the consistent and repeatable visibility provided by the smart turnkey solution. - LINE MANAGER, PRODUCTION, KMSG1, Maruti

Expanding Engagement Across Critical Areas

Component Inspections: Automated checks for defect-free incoming parts.
Sub-Assembly Validation: Ensuring correct assembly and alignment before final integration.
Car Assembly/Body Inspections: Identifying defects in panels, paint, and overall assembly.

The successful deployment in engine bore inspections set the stage for scaling across other production processes.