Case Study: Inovako

Inovako

Automotive industry leader set to improve speed, accuracy, and cost of manufacturing quality control with Z by HP

Inovako was provided loaned HP products from HP.

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Case Study: Inovako

Inside the factory of one of the world’s leading car makers sits an industrial inspection machine that is set to transform the way the automative industry identifies defects in pressed sheet metal. The machine, developed by tech startup Inovako, combines computer vision, AI, and Z by HP high- powered computer processing to spot faults and defects faster, more accurately, and at less cost than before. Within a year, there is likely to be a growing number of Inovako inspection machines in the car maker’s factories across Europe.

Inovako aims to help the automotive industry, and others, address one of its biggest challenges: the cost and brand reputation impact of manufacturing faults. For instance, Automotive News reported that in 2023 alone, Ford paid $1.9B in warranty costs1.

Manual inspection failure rates

Although the industry continuously invests in quality control, it still has challenges. As well as being slow, labor-intensive, and costly, estimates suggest that mistake rates in manual inspections can be as high as 20%2. Before the Inovako solution, one European car maker had

INDUSTRY Technology

OBJECTIVE Improve the accuracy, quality, and cost of inspecting pressed sheet metal parts in automotive manufacturing to reduced vehicle.

APPROACH Utilize HP Z8 Fury to super-charge quality control inspection image processing performance.

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Case Study: Inovako

six engineers inspecting press sheet metal parts on a single production line. “After an hour or so, inspection engineers get tired so their ability to spot defects starts to decrease,” said Emin Eksi, Inovako Managing Director.

The use of automation and technology for inspection is not new. But where Inovako breaks new ground is using AI to bring machine learning, accuracy, and speed into manufacturing quality control. Inovako has developed a pressed sheet metal inspection machine connected to a bespoke industrial PC, but it struggled to process data fast enough.

“Before we got the Z by HP technology, we had tried everything to improve processing power. The problem in a word is speed,” explained Eksi. “A pressed sheet metal part passes through the machine every five seconds. We need multiple images to capture a 360° picture of the part and then we need to process the image data. That requires several algorithms and AI models running at the same time, but we were limited by the existing industrial PC.”

IT MATTERS

• Significantly increases number of images processed per second

• Cuts hours off time taken for AI model training

BUSINESS MATTERS

• Delivers ROI in six months3

• Improves quality control speed, accuracy, and cost

• Helps manufacturers cut vehicle and product recalls

• Enhances post-production diagnostics and iterative manufacturing improvement

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Case Study: Inovako

High-power edged computing

Inovako had considered solutions such as server technology and cloud computing but rejected these because of latency and cost. Because the inspection machine needs to process very high frame rates in real time, the best option is edge computing. Eksi added, “It cannot be any edge computing, it has got to be very powerful edge computing workstations and that is what Z by HP delivers.”

Inovako has replaced its industrial PC with a high-powered HP Z8 Fury G5 workstation with a single Xeon w7-3455 processor, 4x NVIDIA RTX™ 6000 Ada Generation graphics cards with 48GB of GPU memory each, and the Windows 11 Pro 64 OS. This configuration, offering a total of 192GB of GPU memory, is crucial for handling AI model training. The HP Z8 runs Inovako’s DeepMaster AI application which ingests image data from eight cameras, then processes and trains the application to create an AI model for real-time data analysis and defect identification. Models are trained by processing images of an unblemished part. Shop floor engineers can also add their own expertise and experiences to enhance models. When a faulty part is scanned, the inspection machine sounds an alarm, highlights the defect and shows an image of it on-screen in real-time. Every time a defect is identified, DeepMaster models are continuously learning to fine-tune and improve speed and accuracy moving forward.

Deploying more inspection units

Currently, an Inovako inspection machine and HP Z8 sit on one of four production lines at a factory in Turkey. It is used to inspect 15 press sheet metal parts used in manufacturing three car models. Overall, the car manufacture produces up to 2,500 cars a day. Now the manufacturer plans to deploy at least 10 additional inspection machines.

The key benefits our inspection solution delivers are quality and cost reduction. Accuracy is near perfect because automated inspection never

tires like a person, but also because our AI models are continuously learning and improving with the power of NVIDIA RTX 6000 Ada

Generation GPUs in Z by HP workstations. Cost savings are realized because we are helping customers reduce inspection headcount and

better quality reduces the cost and number of vehicle recalls.

EMIN EKSI Managing Director, Inovato

“ ”

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Case Study: Inovako

Inovako also plans to use Z by HP workstations with its other applications which include measuring the fat content in meat products, analyzing x-ray images of castings, and spotting holes in material and clothing. As well as DeepMaster, these application use Inovako’s Lumitec AI-modelling solution for inspecting reflective surfaces like chrome, paint, and glass. Three additional Z by HP workstations have been ordered for a project in Spain, inspecting ignition key production for a luxury car brand.

Using the HP Z8 has had a direct impact on processing speed and capacity. The HP Z8 has improved inspection performance significantly, increasing number of frames per second and cutting hours off time needed for AI model training. The solution is also expected to help car manufacturers reduce the cost of inspections by over 80%3.

Z by HP is critical to Inovako because we need the data processing power of a workstation like the HP Z8 with NVIDIA RTX 6000 Ada Generation GPUs. There is a lot of cost and risk building

your own PC and when we did, we had issues with component compatibility. Using Z by HP

means we do not worry about the hardware, we can focus on what we do best:

developing innovative, leading-edge AI applications.

EMIN EKSI

Managing Director, Inovato

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Case Study: Inovako

ABOUT INOVAKO

Inovako is a deep-tech startup, providing AI and computer vision based industrial solutions. It serves a wide range of industries such as automotive, white goods, machinery, food industry, electronics, and many more with a special focus on inspection applications and shop floor quality and productivity. The company has offices in Turkey and Spain.

Achieving near-perfect accuracy “The key benefits our inspection solution delivers are quality and cost reduction. Accuracy is near perfect because automated inspection never tires like a person, but also because our AI models are continuously learning and improving with the power of NVIDIA RTX 6000 Ada Generation GPUs in Z by HP workstations. Cost savings are realized because better quality reduces the cost and number of vehicle recalls,” stated Eksi. Inovako estimates that the ROI is six months using one of its inspection machines compared to doing it manually in the past3.

One of the Inovako solution’s by-products is being able to build up a historical image record of pressed sheet metal parts. Manufacturers can use this for retrospective investigation, fault diagnostics, improving manufacturing processes, and training.

“Z by HP is critical to Inovako because we need the data processing power of a workstation like the HP Z8 with NVIDIA RTX 6000 Ada Generation GPUs. There is a lot of cost and risk building your own PC and when we did, we had issues with component compatibility. Using Z by HP means we do not worry about the hardware, we can focus on what we do best: developing innovative, leading-edge AI applications.”

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Z by HP for Data Scientists & Analysts

Get rapid results from your most demanding datasets, train models and create visualizations with Z by HP data science laptop and desktop workstations.

Z by HP for Data Scientists & Analysts

Get rapid results from your most demanding datasets, train models and create visualizations with Z by HP data science laptop and desktop workstations.

LEARN MORE

1 AutoNews.com, 21 May 2024 ‘Ford is using factory AI to life quality control results’. 2 Metrology News, March 2024, ‘The Secret Lives of Manufacturing Defects’. 3 Figures based on replacing manual with automated inspections and reducing operators needed for inspections from 6 to 1.

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