T-Erre Diesel Motors | PIQAPART AI Assembly Monitoring Case Study

Case Study – Industrial Assembly

PIQAPART Real-Time Assembly Monitoring

PIQAPART monitors each assembly step in real-time with AI vision. Component placement, orientation, presence verified instantly. Operator receives clear OK/NG feedback. Zero assembly errors. 100% quality assurance before ship.

100%
Step Verification Accuracy
0.5s
Real-Time Feedback/Step
98%
Operator Error Reduction

The Challenge

T-Erre manufactures high-precision diesel motors with complex multi-step assembly. Each motor has 200+ components that must be placed, oriented, and torqued correctly. Manual assembly relies on operator experience and paper checklists—prone to errors that reach customers.

Assembly Complexity at T-Erre

🔧
Multiple Sub-Assemblies — Cylinder blocks, crankshafts, valve trains, fuel systems assembled separately then integrated
📋
High Precision Required — Component tolerances ±0.1mm, torque specs ±5% for engine reliability
⚠️
Manual Inspection Risk — Operators miss orientation errors, miscounted fasteners, misalignment until test run
💰
Field Failures Expensive — Engine failure = recall, customer downtime, reputation damage

PIQAPART: AI-Powered Assembly Copilot

PIQAPART monitors each assembly step in real-time. At every checkpoint, AI vision verifies component presence, position, and orientation. Operator gets instant OK (green) or NG (red) feedback. No surprises at test-run.

Live Assembly Monitoring in Action

PIQAPART verifies component placement and orientation step-by-step. AI detects misalignment immediately. Operator receives real-time OK/NG feedback.

Industrial assembly workflow with PIQAPART monitoring. Each step verified, each component accounted for. Zero errors reach test.

PIQAPART Step-by-Step Process

1
Capture Assembly Frame
Camera captures current assembly state from fixed angle at each workstation.
2
AI Verification
Vision AI checks: component present? Correct position? Correct orientation? Fasteners tight?
3
Real-Time Feedback
Operator sees GREEN (OK – continue) or RED (NG – fix before proceeding) within 0.5 seconds.
4
Logging & Traceability
Every step photographed, timestamped, linked to motor serial number. 100% audit trail.

PIQAPART Benefits for T-Erre

✅
Zero Assembly Defects
100% step verification. Every component position confirmed before moving to next step. No defects reach test.
⚡
Faster Assembly
Operators don’t need to double-check or wait for supervisor review. AI confirms instantly. 25% faster cycle time.
📊
Complete Traceability
Every motor assembly step logged with photos, timestamps, operator ID. Compliance & warranty support.
👤
Operator Confidence
No guessing. AI confirms every action. Reduces stress, improves job satisfaction, cuts training time.
💰
Prevents Recalls
Assembly errors caught at workstation, not in field. Saves €500k+ per recall avoided.
🎯
Continuous Improvement
Data shows which steps cause most errors. T-Erre uses insights to improve assembly design & tooling.

Proven Results at T-Erre

100%
Step Verification
Every assembly step verified before proceeding. No manual inspections, no guesswork.
98%
Error Reduction
Operator errors dropped from 2-3% to <0.1%. AI catches misalignment, wrong parts, skipped steps.
25%
Faster Assembly
No re-inspection delays. Operators move through steps 25% faster with AI confidence.
0
Field Escapes (6 months)
Zero assembly-related failures since PIQAPART deployment. First time perfect.

Transform Your Assembly with PIQAPART

See how AI vision can eliminate assembly defects in your production. Request a demo with your actual assembly workflow.

Request Demo →

Frequently Asked Questions

Can PIQAPART handle multiple assembly variants (different models)?▼
Yes. PIQAPART is trained on multiple motor variants. Operator selects model at start of assembly. AI adapts verification rules accordingly. T-Erre runs 5 different motor models on same line.
How fast is the AI feedback?▼
0.5 seconds from step completion to operator feedback. Operator completes assembly step → camera captures → AI processes → green/red light triggers. No line slowdown.
What if AI says “NG” but operator disagrees?▼
Supervisor can override with password. Override is logged (who, when, why). AI learns from overrides. False positive rate drops after each override correction.
Does PIQAPART check torque values?▼
PIQAPART monitors fastener visual presence and positioning. For torque verification, integrate with smart torque wrenches (wireless connection). Combined system gives 100% assembly verification.
How is the data used for continuous improvement?▼
Dashboard shows: which steps most error-prone, which operators need coaching, failure pattern analysis. T-Erre used this to improve workstation design, reducing errors by an additional 40%.
What’s the training time for operators?▼
30 minutes hands-on introduction. Most operators master system in one shift. AI feedback is intuitive (green/red light). After day 2, operators prefer PIQAPART to manual assembly.