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Through innovative AI-powered computer vision and advanced analytics, Expand My Business revolutionized the client's steel production processes. We tackled critical defects, enhanced precision, and boosted efficiency, resulting in remarkable cost savings and revenue growth.
The company faced two major production challenges:
These issues led to substantial financial losses, with rejected shipments costing millions and total annual losses reaching around $150 million. The persistent problems also damaged the company's reputation and market position.
To address these challenges, Expand My Business suggested the implementation of a comprehensive AI-powered quality control system, featuring:
Advanced Visual Inspection
High-resolution and precision cameras were installed along the production line and at the rolling station, capturing detailed visual data and measuring coil gaps with sub-millimeter accuracy to detect and address defects and precision issues.
Real-Time AI Analysis
Cutting-edge machine learning algorithms processed camera feeds in real-time, identifying and flagging potential problems before they could escalate, ensuring early detection and resolution.
Immediate Notifications
A real-time alert system was implemented to immediately notify operators of detected issues, enabling prompt intervention and significantly reducing waste.
Comprehensive Data Analytics
A robust data analytics platform was established to analyze production data, uncover trends, and recommend process improvements, driving enhanced efficiency and quality in manufacturing.
The implementation of these solutions yielded significant improvements:
The rate of rejected shipments decreased from 5% to 0.2%, resulting in annual savings.
The failure rate in the rolling process dropped from 3% to 0.07%, saving a good amount annually.
Company revenues grew by 24% to approximately by the end of the second year.
The implementation of AI-powered computer vision and advanced analytics transformed the company’s production processes, resolving critical quality and precision issues. This not only resulted in substantial cost savings and efficiency gains but also reinforced the company's competitive position in the global market. The success of this technology paves the way for future innovations and applications across various industries.
