Overview

An aviation tier 1 supplier struggled with the limitations of manual coating inspections, which relied on human judgment and were prone to inconsistency, fatigue, and environmental factors. Subtle defects on complex surfaces were often missed, leading to slower inspections, increased rework, and inconsistent quality control. By implementing an AI-driven inspection system with predictive analysis, the organization improved accuracy, reduced inspection time by 70%, cut rework costs by 40%, and minimized common mistakes. Using past data, the AI provided advisory insights to prevent coating errors. This resulted in a 30-50% reduction in defects and ensured compliance with aerospace standards.

Challenge

Manual inspection methods rely heavily on human judgment and can be inconsistent and error-prone, particularly when inspecting complex surfaces or identifying subtle defects. Fatigue, environmental factors, and limited visibility further impact the accuracy and speed of manual inspection. Moreover, the subjectivity involved in interpreting coating defects can lead to variations in quality control, making it challenging to ensure uniformity and reliability across different inspections. Without AI, the inspection process can be slow, costly, and less effective in detecting early-stage or hidden defects.

Common Defects and Causes:

• Blisters: Caused by trapped air or moisture beneath the coating.
• Craters: Formed due to surface contaminants like oil, grease, or dust.
• Orange Peel: Results from improper application techniques or incorrect spray settings.
• Runs/Sags: Occur from over-application or incorrect paint thinning.
• Pinholing: Happens when solvents evaporate too quickly from the wet coating.
• Wrinkles: Caused by improper drying or curing of the top layer.
• Cracking: Due to the over-application of coatings or excessive hardness of the material.

Solution

The AI-based painting inspection setup revolutionizes the quality control process by automating defect detection, ensuring higher accuracy, and reducing human errors. This system integrates cutting-edge vision technology, advanced illumination, and real-time processing within a dedicated paint inspection booth, ensuring comprehensive and reliable paint quality assessments. Below are the key features and specifications of this innovative solution.

Key Benefits

• Real-Time Defect Detection: AI-powered vision systems consistently detect surface-level defects such as blisters, cracks, and runs. These systems are trained to identify even the smallest inconsistencies that may be missed by human inspectors due to fatigue, environmental factors, or varying lighting conditions, ensuring more reliable results.
• Faster Inspections: AI systems significantly reduce the time required for compared to manual methods. By scanning large aircraft surfaces quickly, AI can perform comprehensive inspections in a fraction of the time, allowing continuous operation and minimizing aircraft downtime during maintenance or quality control checks.
• Predictive Maintenance: AI systems gather historical data and use predictive analytics to foresee potential coating failures before they happen. By identifying trends and early warning signs, AI helps operators prevent costly rework, minimize material waste, and reduce maintenance costs, enhancing operational efficiency.
• Consistent Quality: AI ensures precise color matching and uniformity in surface finishes. By leveraging advanced image processing techniques, AI can maintain consistent coating quality across different surfaces, ensuring that coatings meet the required aesthetic and performance standards with little room for error.
• Enhanced Compliance: AI systems automatically check coatings against industry standards, such as thickness, adhesion, and color matching. This automation ensures that all applied coatings adhere to the strict aerospace regulations, minimizing the risk of non-compliance and improving overall safety and performance.

Results

 

• Reduced Defects: Expect a 30-50% reduction in coating defects through early detection and correction.
• Faster Inspection Times: AI-driven systems can complete inspections up to 70% faster than manual methods.
• Lower Rework Costs: AI can help reduce rework costs by up to 40% by ensuring that defects are caught before they become critical.
• Enhanced Compliance: Improved adherence to aerospace coating standards, ensuring a higher level of safety and reliability in coatings.