Manufacturing – EV Battery Pack Assembler: Line Balancing & Safety Interlock AI

Industry: EV battery assembly. Complexity: OEM traceability mandates.

Siloed data, late defect discovery, serialization risk.

Vision Agent, Telemetry Agent, Serialization Agent, Containment Agent.

1. Station signals.
2. AI inspects welds.
3. Torque/thermal join.
4. Serial validation.
5. OEM label print.
6. Exception hold.
7. Analytics to engineering.

Inspect Agent, Correlation Agent, Serial Agent.

Edge vision, historian taps, strict schemas for OEM.

PLC data historian, MES, PostgreSQL, OpenAI, vision models

Customer-reported defects −62%; line stoppage diagnosis time −57%; serialization errors −94%; rework hours −48%.

Build: 13 weeks. Deploy: dual shift. Optimization: 12 weeks OEM spec updates.