AI-driven visual analytics for a Global Engineering Leader

Client

The client is a specialized division within a global manufacturing group, recognized for delivering high-precision components that ensure reliability and efficiency in automotive, industrial, and mobility applications. With deep expertise in advanced engineering and an R&D footprint, the organization supports worldwide production by supplying mission-critical bearings and structural components for engines, transmissions, and chassis systems.

Facing increasing demand for quality and innovation amid the shift toward electrification and intelligent mobility, the client prioritized modernizing its inspection processes to maintain a competitive edge, uphold strict safety standards, and enable continuous improvement across global operations.

Market trends in precision engineering and quality inspection

In 2025, the global bearing and component manufacturing sector is experiencing exponential growth, propelled by rising demand from automotive, industrial automation, and renewable energy markets. The shift toward hybrid and electric vehicles, especially in Japan, accelerates the need for advanced, durable bearings and high-precision components to support new powertrain designs and intelligent mobility platforms.

Technological advancements, such as ceramic and hybrid bearings, integrated sensor technologies, and AI-powered inspection systems, enhance product longevity and quality assurance. At the same time, manufacturers face challenges from volatile raw material costs and increasing pressure for sustainable, energy-efficient solutions. Industry leaders invest in digital inspection platforms and process automation to stay competitive, improve accuracy, reduce cycle times, and enable proactive quality control at scale.

Market trends in precision engineering and quality inspection

Business challenges

Slow, labor-intensive inspection cycles: Manual weld quality checks took up to 14 hours per unit, delaying production schedules and reducing throughput.
Heavy reliance on expert operators: The need for specialized skills made inspections resource-intensive, complex to scale, and vulnerable to workforce shortages.
Inconsistent quality and missed defects: Visual inspections lacked standardization, increasing the risk of undetected flaws and jeopardizing product reliability and compliance.
Limited data and delayed reporting: Manual processes provided few actionable insights, hindering root-cause analysis, trend identification, and timely corrective actions.

LTIMindtree solution

LTIMindtree deployed an Digital Visual Inspection System tailored for high-precision manufacturing environments. The system uses AI, computer vision, and edge processing to transform weld quality control.

Custom-built hardware and vision systems

Integrated laser emitters, depth-sensing cameras, and industrial-grade sensors to enable high-resolution weld scanning in both handheld and stationary modes.

Automated defect detection with AI-powered analytics

Created 3D profiles from weld images, using advanced AI models to consistently identify disjoints, surface defects, and quality deviations, reducing dependency on manual expertise.

Deskilled, scalable operations

Designed the inspection process for easy use by operators with minimal training, supporting consistent quality assurance and rapid scale-up across production lines.

Real-time digital reporting and analytics portal

Provided immediate insights and trend analysis through a web-based dashboard, enabling proactive quality control, faster decision-making, and full traceability for compliance audits.

Business benefits

70% reduction in inspection cycle time

Automated visual analytics cut weld inspection from 14 hours to just 4 hours per unit, accelerating production throughput.

Consistent, AI-driven accuracy

Standardized, automated defect detection minimized human error, ensuring higher product reliability and fewer missed flaws.

Deskilled operations for scalability

User-friendly system enabled operators with minimal training to perform inspections, reducing reliance on scarce expertise and simplifying workforce planning.

Real-time insights and traceability

Digital reporting delivered immediate visibility into defect trends, supporting proactive quality improvement, faster root-cause analysis, and streamlined compliance documentation.

Conclusion

The client redefined weld quality control by deploying LTIMindtree’s Digital Visual Inspection System, cutting inspection time by 70%, standardizing defect detection, and empowering teams with real-time insights. This transformation accelerated production, improved reliability, and created a scalable foundation for ongoing process innovation.

With AI-driven analytics and digital traceability now embedded in operations, the organization is well-positioned to meet rising quality demands, adapt to new manufacturing technologies, and maintain its leadership in precision engineering.

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Client

Market trends in precision engineering and quality inspection

Business challenges