AI-Powered Fault Detection for Paint Shops

Integrating artificial intelligence (AI) into production lines is steadily becoming a prominent consideration across all sectors of manufacturing, and AI tools that are tailored for surface finishing are beginning to hit the market.

The latest software tool from Dürr’s (Southfield, Michigan) DXQanalyze product family comprises AI algorithms and data-driven machine learning, enabling it to detect systematic fault patterns and their causes early. With the Advanced Analytics module, the first market-ready AI application for paint shops, DXQplant.analytics has access to a wealth of data for fault analysis. The software can detect whether the fault is a one-time or systematic issue, such as recurring quality defects with particular colors. Data from recognized patterns can identify the process step responsible for the fault. This makes it possible to analyze systematic production quality deficiencies, which can be hard to recognize, and quickly identify and fix their causes. Paint shops should expect to see increased first-run rates using the tool.

Digital file for each body

The basis of DXQplant.analytics is quality information recorded digitally for each workpiece during surface inspection. In addition, process parameters, alarms and anomalies from the individual processing steps supplement the workpiece-related data records. This reportedly creates a digital file for each body that models the entire production and life cycle, including any faults found. Machine learning can help identify patterns and correlations in data records. If there are frequent contaminants in the paint, Dürr says the software will detect this and immediately assign information about the underlying cause to the fault pattern.

Easier fault analysis

Detecting recurring paint defects is very laborious, and locating faults is time-consuming and expensive. DXQplant.analytics flags problematic fault sources to the quality manager and provides targeted help with analyzing the cause. Correlating graphics and automatically generated reports document insights to share with colleagues, workers and management. Integrated documentation functions are said to enable the DXQplant.analytics user to save and manage defined optimization measures and track their impact on quality. Therefore, DXQplant.analytics helps the paint shop operator increase the first-run rate in a targeted way, according to Dürr, thus boosting overall equipment effectiveness.

With DXQsupport, Dürr offers a comprehensive service package for use and maintenance of its digital solutions. The company provides support for the entire software life cycle, which is said to increase and maintain availability, performance and quality. In addition to regular updates, Dürr’s team of experts constantly monitor live production activity to react quickly in the event of failures or irregularities. These services are accompanied by a comprehensive modular training catalog, which Dürr says enables operators to leverage the full potential of their digital portfolio.