Case Study

Transforming Automotive Manufacturing with Vision Intelligence

The automobile industry is evolving faster than ever — with rising quality expectations, complex assembly lines, and a growing focus on safety and sustainability. Amid this transformation, VijAI AI Visio is enabling automobile plants to achieve zero-defect manufacturing, enhanced worker safety, and data-driven productivity through its intelligent AI Vision modules: DriveAI, PulseAI, and InspectAI

PPEAI

Automatically verifies whether automotive maintenance technicians are wearing the correct PPE before entering workshop bays or high-temperature zones. Reduces injury risks and boosts EHS audit readiness

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FIREAI

Identifies smoke, sparks, or overheating around engines, battery lines, fuel systems, and welding areas in real time — enabling teams to act instantly and prevent escalation.

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GESTEAI

Prevents distractions inside workshops by detecting unsafe gestures such as mobile usage, careless movement, or inattentive walking near active automotive machinery.

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DRIVEAI

DriveAI is a dedicated AI vision module for vehicle and human movement safety in logistics yards, assembly docks, and unloading zones. It integrates with traffic lights, hooter alarms, and CCTV cameras to ensure collision-free and compliant operations

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ZONEAI

Monitors restricted workshop zones and allows only authorized staff—instantly alerting teams to prevent unauthorized presence in paint shops, testing tracks, or assembly bays.

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PULSEAI

PULSEAI acts as the nervous system of the plant, capturing every movement, action, and event to deliver real-time performance metrics through vision analytics.

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SAFEAI

Detects unsafe acts during vehicle servicing like climbing without support, bypassing safety rails, or improper lifting of heavy automotive components. Enables early intervention and training.

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SECUREAI

Uses facial recognition and motion detection to prevent unauthorized entry into automotive R&D labs, storage areas, and vehicle test zones—cutting security breaches by 90%.

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GUARDAI

Continuously checks machinery and tools to ensure protective guards are in place after servicing. Prevents unsafe restarts of lifts, presses, and automated repair systems.

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INSPECTAI

INSPECTAI brings machine-level precision to the quality assurance process. It identifies surface defects, paint issues, missing bolts, misalignments, and sealant irregularities — all in real time using advanced vision algorithms.

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VijAI AI Vision, developed by VB Group, brings AI-driven visual intelligence to every corner of the automobile plant. Using a combination of deep learning, computer vision, and real-time analytics, VijAI enables manufacturers to monitor, detect, and optimize processes automatically.

VijAI Impact Statistics

Reduced by 80%

Safety Incidents

99% accurate

Defect Detection

Under 2 minutes

Inspection Time

Real-time analytics

Production Efficiency

The Challenge

Modern automobile manufacturing plants operate like living ecosystems — thousands of components, hundreds of workers, and dozens of robotic cells working in unison. Yet, traditional visual inspection and safety monitoring methods are manual, error-prone, and reactive. Plants struggle with:

Missed surface defects or paint inconsistencies

Unsafe worker-vehicle interactions in logistics areas

Delays in assembly line quality checks

Lack of real-time visibility into machine and human efficiency

Safety. Quality. Precision. Powered by AI.
From drive path monitoring and assembly line vision analytics to automated quality inspection, VijAI AI Vision is setting new benchmarks in how automobile factories function. It's more than technology — it's the AI-powered vision of the future factory