Stamped appearance parts dread a single scratch or shallow dent—small and low-contrast, exactly what manual eyes miss most. A body-shop plant used DaoAI AI-AOI to push the escape rate down to two per thousand.
Stamped sheet-metal parts are mostly visible outer panels, where any scratch, dent or impression directly affects vehicle appearance quality. At this plant such defects are often only a few tenths of a millimeter, with extremely low contrast on reflective metal surfaces. Manual inspection tires easily and misses defects, with a measured escape rate as high as 2.8%. Once defective parts flowed downstream or to the customer, rework and claim costs were high and the reputation of appearance parts took a direct hit.
Seeing a 0.3mm Scratch Clearly
DaoAI AI-AOI surface inspection optimizes imaging and lighting for reflective metal surfaces, pairing them with a deep-learning model that recognizes scratches, dents, impressions and pinholes, reliably catching fine defects at the 0.3mm class. Iterated continuously on on site samples, the model holds a high detection rate while effectively suppressing false calls, reaching 97% overall accuracy and enabling full, part-by-part judgment of appearance parts.
- 0.3mm-class detection: fine scratches and shallow dents reliably caught
- 97% accuracy: high detection with low false calls, reducing needless rework
- Escape rate 2.8% → 0.2%: customer-side outflow risk sharply reduced
- Metal-surface optimized: imaging and lighting tailored to reflective outer panels
Cutting the escape rate from 2.8% to 0.2% puts the reputation of appearance parts back in your own hands.
After go-live, the plant achieved full surface inspection of stamped appearance parts, the customer-side escape rate fell from 2.8% to 0.2%, appearance complaints and claims dropped markedly, and both quality stability and delivery confidence rose in step.
FAQ
What problems exist in the manual visual inspection of stamped sheet metal parts?
The defects of stamped sheet metal parts are small in scale and low in contrast. Manual visual inspection is prone to fatigue and missed judgments. For example, the actual missed-detection rate of a body parts factory is as high as 2.8%. Defective parts flowing downstream will increase costs and damage the reputation.
What detection effects can DaoAI AI-AOI achieve?
DaoAI AI-AOI surface defect detection can stably detect 0.3mm - level subtle defects. The overall detection accuracy reaches 97%, and the missed-detection rate drops from 2.8% to 0.2%, reducing appearance complaints and claims.
What optimizations has DaoAI AI-AOI made for the metal reflective surface?
DaoAI AI-AOI has optimized the imaging and lighting solutions for the metal reflective surface, and cooperates with the deep-learning model to identify defects, effectively dealing with the detection problems of reflective cover parts.