Robots, artificial intelligence and human sensitivity: How the Porsche plant in Leipzig ensures that only vehicles with the finest finish leave the paint shop.
symbiosis of technology and craftsmanship
Car manufacturers have been using robots in their paint shops for years. This technology not only improves employee efficiency and safety, but also ensures more consistent results. Nevertheless, the human eye remains a decisive factor in detecting possible paint defects.
How technology optimizes the painting process
Until a few years ago, visual inspections had to be performed manually – a task that was both time-consuming and error-prone. At the Porsche plant in Leipzig, this process was revolutionized by modern technology. Two robot arms scan the body of every series vehicle manufactured in Leipzig.
An image is taken every 2,5 millimeters, a total of about 100.000 images per vehicle within 72 seconds. The data is analyzed by a network of ten powerful image processing computers that can detect even the smallest errors. Unevenness or dust particles - so-called inclusions - are identified precisely and objectively.
millimeter-precise error detection
The detected abnormalities are recorded with millimeter precision. This data is then forwarded to the final production. A detailed 3D model visualizes the position of the defect and provides additional information, such as high-resolution close-ups and a classification of the defect type. This enables the team in the final production carry out paint corrections in a targeted and efficient manner.
AI in quality control
Using AI and deep learning algorithms, every error is not only recorded but also categorized. This data enables a precise analysis of the entire painting process, allowing weak points to be identified and remedied at an early stage. The automated inspection process, which takes less than 100 seconds, guarantees Porsche's usual high quality standards.
What used to be a lengthy and labor-intensive process is now faster, more efficient and more error-free. You can find further details and exclusive insights into the entire process in the video. Image and video credits/source: Porsche / This content was created using AI and reviewed by an editor.