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Re:F-150 Lightning Recall Due to SK Cells by londons_explore on Thursday March 23, 2023 @09:18AM (#35274295)
If I were designing a production line, every step of the process would record video footage of every part being made, tested, and fitted.

Then, if any quality issue is identified, the footage can be checked to see exactly which cells that went into which cars were faulty.

It's far quicker to check 30 seconds of video to verify that a worker remembered to tighten some critical bolts than to recall the car and have a service technician pull the whole thing apart to find that this car was fine after all.

Re:F-150 Lightning Recall Due to SK Cells by sbradford26 on Thursday March 23, 2023 @09:37AM (#35274578)
Processes like that work for bespoke things like the mars rovers and satellites. But for a mass produced product you will quickly run into a scale and storage issue. Ford is planning on making 150000 F150 Lightnings so around 400+ per day. With ever step expected to be completed in a couple minutes you are going to have to track tens of thousands of videos clips per day and store and archive them. Then for recall work you will have store the videos for around 15 years. The cost to maintain all of that infrastructure and storage is most likely not worth it.
Re:F-150 Lightning Recall Due to SK Cells by thakoppno on Thursday March 23, 2023 @10:35AM (#35275471)
> The cost to maintain all of that infrastructure and storage is most likely not worth it.

Your analysis is likely correct; but at the same time, a system like this has never been more affordable, possible.

Also, imagine getting a video of your brand new car’s construction at the time of purchase.

Re:F-150 Lightning Recall Due to SK Cells by sbradford26 on Thursday March 23, 2023 @10:42AM (#35275589)
So Ford is providing pictures for people who ordered Ford Broncos currently. And for a method of keeping customers interested in the vehicle they ordered I think it is a really good tactic.

https://www.motor1.com/news/542024/ford-bronco-assembly-line...

Re:F-150 Lightning Recall Due to SK Cells by detrites on Thursday March 23, 2023 @10:48AM (#35275663)
I wonder how well some kind of bespoke batch-processing video codec would work on production line footage where the endless repeats of the same mechanical motions continue for hours and across days/weeks? Encode only the difference between cycles.
Re:F-150 Lightning Recall Due to SK Cells by specialist on Thursday March 23, 2023 @11:17AM (#35276177)
Just store the diffs.
Re:F-150 Lightning Recall Due to SK Cells by dylan604 on Thursday March 23, 2023 @02:01PM (#35278787)
just store the one cycle and repeat it. nobody will know the diff
Re:F-150 Lightning Recall Due to SK Cells by Kirby64 on Thursday March 23, 2023 @11:01AM (#35275878)
This doesn't address soft failures, though. What if the worker didn't fully tighten them to spec but did partially tighten them? What if the bolt was cross-threaded, how could you tell from a video? The amount of camera angles and quality of cameras needed to actually make these calls seems like it would be nigh-impossible.

The data-to-noise ratio of video is pretty bad (most of it going to be wasted on data for... the factory floor or whatever), compared to something like logging the torque of every bolt on the line (which, they already do in some situations).

Re:F-150 Lightning Recall Due to SK Cells by LeifCarrotson on Thursday March 23, 2023 @11:33AM (#35276402)
Controls engineer who's designed several production lines for tier 1 automotive suppliers and a couple for OEMs reporting in... you'd be wrong, video footage is kind of useless, because you can't query it automatically.

Instead, our PLCs (programmable logic controllers) report to in-line vehicle sequencing databases. Every step of the process is logged to ILVS, and - unlike our work with furniture or consumer goods manufacturers - that is the only thing they care about. It doesn't matter if you can see that there's a physical assembly with properly torqued bolts that we've delivered to Ford's loading docks, we only get paid if the torques are correctly recorded for that serial number in ILVS. Each line tracks each part with serialized 2D barcodes. Any time a measurement is made or an operation is performed, the PLC will trigger an upload to record that data in ILVS, whether that's a barcode quality grade of the 2D scanner camera, or a force measured to drive a clip in, or a temperature measured while setting a heat stake, or the current drawn by a sensor, or...anything. For jellyroll battery winders I've done, that will include obvious stuff like Hipot test results but also minutiae like the row and column and stack height in the tray that transfers the jellyroll between the winding machine and the pack assembly machine.

This sort of database provides not only recall protections, but also ANOVA gauge reliability and repeatability to retain control over the process, and predictive maintenance to know when a machine or mold is wearing and causing a trend in the measured data (even if it's all within acceptable tolerance).

If I was recording bolt torques that were manually driven by a human (rather than a robot), I'd probably use a wireless electronic torque wrench with a UWB RFID tag on the socket (or some discrete tags on the jig) to verify that you'd reached the appropriate torque at the appropriate location. You'd be able to automatically query the database for the barcode of the assembly with any data that came with its forming/casting/other production data, the lot ID of the bolt, the calibration source of the wrench, the employee ID, the time and date that it was torqued, how much time it took the operator to torque each bolt, and on and on.

We do still have video cameras pointing at our machine recording to a ~1 week circular buffer, but that's more so that we can reconstruct the sequence of events that led to a machine fault.

Re:F-150 Lightning Recall Due to SK Cells by derivagral on Thursday March 23, 2023 @12:34PM (#35277324)
> you can't query it automatically

Considering the more interesting applications would likely have barcodes, couldn't this be done with modern recognition and tagging?

Re:F-150 Lightning Recall Due to SK Cells by HeyLaughingBoy on Thursday March 23, 2023 @06:33PM (#35282349)
Now you have to make sure that the camera has line of sight to the barcode!
Re:F-150 Lightning Recall Due to SK Cells by londons_explore on Thursday March 23, 2023 @01:22PM (#35278101)
video recordings would be in addition to what you've said, to catch things that nobody thought to record or check...

Things like "we've had a high number of complaints of wind noise in cars from the front right door seal, but only those made on the night shift".

Then you check the footage and see the worker is stretching the seal while pushing it on, breaking it slightly, and then it fails a few weeks later.

You never thought to have a database field for 'number of newtons of stretch force while putting seal on'... But the video can explain it...