How AI Tools Improve Vehicle Design

By Sarah Foss and Mariana Reyes Hernandez

Modern vehicle manufacturing demands unparalleled precision. From the intricacies of casting parts to the complexities of metal stamping, each stage in production is designed to be both scalable and adaptable to the unique needs of different assembly lines.

As vehicles progress through General Motors (GM) manufacturing facilities, they undergo numerous inspections and evaluations. To elevate quality controls, GM leverages cutting-edge technology such as machine learning and AI analytics, streamlining the process, enhancing accuracy, and accelerating decision-making. This advanced technology not only improves operational efficiency but also enables GM to deliver superior products for its customers.

Below are examples that illustrate how GM is innovating its manufacturing processes through technology. Many of these advancements have garnered recognition, including prestigious Boss Kettering Awards that honor projects shaping the future of GM.

Device Level Analytics (DLA)

DLA consists of a network of sensors that act as the plant’s eyes, continuously monitoring and analyzing operational performance—gathering data on vibrations, electrical currents, and more. This information is instrumental in scheduling proactive maintenance, significantly reducing unexpected machine failures and downtime.

As DLA technology expands throughout GM’s facilities, it will utilize machine learning algorithms and AI capabilities to identify problems more swiftly and accurately.

For instance:

• Traditionally, team members would need to manually inspect all 5,600 vehicles in a batch.

• Utilizing data from DLA, the team identified missed welds and quickly pinpointed the affected vehicles, narrowing the focus from thousands down to fewer than 10.

CAPTION: DLA sensors monitor conveyor systems transporting vehicles through the plant. Data is relayed to a central command center and compiled into reports that highlight any anomalies, indicating potential repair needs.

WeldBrAIn™

The welding process is vital during vehicle assembly since it forms the structural integrity of the vehicle. Traditionally, quality checks in the Body Shop required a single employee to physically inspect weld strength. Now, advanced technology provides insights that are invisible to the naked eye.

At Factory ZERO, GM is implementing WeldBrAIn™, a proprietary system that monitors production quality. This AI-enabled tool has transformed the quality inspection process, allowing real-time analysis of all welds on every vehicle, rather than just four parts per shift.

CAPTION: Workers utilize the WeldBrAIn™ dashboard to verify the quality of welds across an entire vehicle. The same dashboard is used on the floor for further inspections.

Vision Systems in Paint Repair

In the paint shops at GM, team members traditionally inspect surfaces for defects by touch and visual assessment. Despite ongoing efforts to enhance the quality of the final coat, subtle quality issues can still arise that are hard to detect.

For example:

• In the Spring Hill and Flint facilities, Finesse Paint Repair camera systems have been installed to identify paint quality issues as vehicles move through production.

• These ‘superhuman eyes’ can detect imperfections at a microscopic level, leading to quicker and more informed decisions, ultimately resulting in a superior paint finish for customers.

• This technology also gathers defect data, providing valuable real-time feedback to GM Paint Process Engineers, facilitating improvements and helping to refine the painting process to prevent future defects.

CAPTION: Vision systems assess paint quality as vehicles pass through the shop, correcting issues that are not visible to the naked eye.

Innovative tools such as Device Level Analytics, WeldBrAIn™, and advanced vision systems empower GM employees to identify issues earlier, maintain high standards of quality, and make quick, confident decisions. This approach ensures GM consistently delivers top-quality products while fostering a culture of safety, accountability, and continuous enhancement across every production shift.

By Sarah Foss and Mariana Reyes Hernandez