ZERO DEFECTS THE MARTORELL PLANT TRANSFORMS TOWARDS ELECTRIFICATION. A GOOD EXAMPLE OF OUR COMMITMENT TO EXCELLENCE AND EFFICIENCY IS THE ZERO DEFECTS PROJECT, AIMED AT AVOIDING ANY DEFECTS BEFORE THE END OF THE PRODUCTION LINE READ MORE READ MORE MIGUEL ÁNGEL ESCUDEROHEAD OF BODYWORK PROCESSES AND ZERO DEFECTS PROJECT “Many of the interventions included in the project affect not only new models, but also those that are currently in production” PRESSES BODYWORK PAINTING ASSEMBLY The Zero Defects project is vital to ensure our vision for the future and the quality of our products. Our aim is for processes to be self-regulating, learning and improving all the time. The Zero Defects Vision cuts across all areas, as it applies to all pro-duction areas: Press Shop, Body Shop, Paint Shop and Assembly Shop. Although it was launched in 2022, the actions it contains are already being im-plemented and will continue to be integrated into the production process over the coming years. The aim is to use automation to reduce vehicle produc-tion times, eliminate rework and maximise direct production inputs. The project takes into account the quality of parts provided by suppliers and the different product variants available, always en-suring production in compliance with current reg-ulations. It is a commitment to minimising defects on the assembly line, which requires not only the development of robust processes, but also the training of SEAT S.A. professionals to ensure their successful implementation. — The commitment to digitalisation and innovation is crucial in the Press Shop, where, as in the rest of the company, a major transformation is currently underway. The project focuses on reaching excellence in the production of press lines through process optimization. To achieve this ambitious goal, we focus on four pillars: - An in-depth analysis of variation in the mechanical characteristics of the sheet metal formats that reach our material supplier’s presses. - Online detection of cracks using cameras with algorithms managed by artificial intelligence. - Protecting dies with cameras that monitor any ‘foreign bodies’ possibly falling in, such as screws accidentally that may cause breakage and therefore production stoppages. - Autonomous production through artificial intelligence generating an ecosystem of production data, press monitoring and quality control. PRESSES The Body Shop is closely associated with the product and the incorporation of new technologies. In this case, the Zero Defects Vision includes actions such as monitoring and self-correcting through the use of robots, as well as the replacement of physical parts, point templates and documentation by digital means. Other additional actions include: - Monitoring the process and product through in-line measurement systems without the need for correlation. It is important to note that, after Tavascan, the urban electric vehicle will be the Consortium’s first project to use this technology. - Surface monitoring system for detecting defects in the sheet metal through machine learning, a process that in the future will be carried out using cameras. - Implementation of vision cameras to ensure the unloading process of assemblies and parts, from containers to the installation. - Quality Control Loop (Regelkreis) between the assembly, painting and bodywork areas at the adjustment level, digitised, automated and in real time through the cloud. BODYWORK The Paint Shop was the first to incorporate the detection and repair of surface defects throughout the Volkswagen group. It has also been possible in this area to link the positioning information and characterisation of the defects provided by the tunnels, with robotic stations capable of reworking the defects in touch time. It is worth highlighting the following measures regarding Zero Defects: - Two defect detection tunnels after primer layer. - Two defect detection tunnels at the ends of the Painting line. - Two stations for sanding primer defects. - One station for sanding/polishing defects in the final layer. PAINTING As part of the Zero Defects Vision, the incorporation of automatic controls with artificial vision cameras is vital in the Assembly Shop. These include: - Assembly tunnel that automatically measures flushes and excesses using a system made up of 50 cameras. - A system that links the data of this assembly tunnel with another that exists in the Body Shop. In this way, measures can be taken quickly and defects can be anticipated in the event of any incident. - Automatic monitoring of defects using AI cameras. Consortium systems are currently being developed in the Assembly Shop to improve and optimise the management of these cameras. This will help to incorporate many other additional controls, thereby ensuring the quality of our cars. ASSEMBLY