Case Study – Industrial Assembly

PIQAPART Real-Time Assembly Monitoring

Q: 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.

Q: 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.

Q: 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.

Q: 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.

Q: 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%.

Q: 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.

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.

Book your free test See pricing

PIQAPART Real-Time Assembly Monitoring Demo - Component Verification

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

Operator at an assembly rack where a light marks the next bin to pick from — Pick to light

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

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

PIQAPART Benefits for T-Erre

01
Zero Assembly Defects
100% step verification. Every component position confirmed before moving to next step. No defects reach test.
02
Faster Assembly
Operators don’t need to double-check or wait for supervisor review. AI confirms instantly. 25% faster cycle time.
03
Complete Traceability
Every motor assembly step logged with photos, timestamps, operator ID. Compliance & warranty support.
04
Operator Confidence
No guessing. AI confirms every action. Reduces stress, improves job satisfaction, cuts training time.
05
Prevents Recalls
Assembly errors caught at workstation, not in field. Saves €500k+ per recall avoided.
06
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.

Free feasibility test

Transform Your Assembly with PIQAPART

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

parts or photos: 20; parts or photos
days to results: 5-7; days to results
no commitment: €0; no commitment

Results before contract Book your free test See pricing +39 049 825 6850

FAQ

Frequently Asked Questions

Another question? Call us on +39 049 825 6850 or email info@logirobotix.com.

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.

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