Customer: General Motors Role: Vision / Automation Engineer Via: Ascension Automation Solutions (contracted to ATS) Location: Ramos Arizpe, Mexico Timeline: Jan – Jul 2024
The Project
Commissioned error-proofing inspection systems for GM’s EV battery lines. Started at the ATS campus in Cambridge, Ontario for Factory Acceptance Testing, then deployed on-site in Mexico.
Factory Acceptance Test (FAT)
Custom-built and developed the camera system before deployment. Used Matrox cameras with Design Assistant software — a flowchart-based tool for programming inspection logic.
FAT setup validating inspection before shipment:
On-Site Installation
At Ramos Arizpe, Mexico, I oversaw hardware installation and verified delivered parts against ATS design specifications.
Key tasks:
- Supervised mounting and placement of all components
- Directed camera and lighting setup — adjusting angles, focus, and exposure
- Optimized inspection programs using dummy samples from GM
- Programmed web interface for on-the-fly parameter tuning
Troubleshooting
Resolved various field issues:
- Cameras restarting randomly due to power problems
- Inspection images not saving to camera computer
- Unreliable inspections after program updates
Also gained hands-on PLC and HMI experience integrating stack lights, barcode readers, and torque controllers.
Project Phases
Aligned work with plant milestones:
- N1/N5: Initial setup and verification
- N30: Refinement and pre-production prep
- PPAP: Validation to GM quality standards
- Production: Optimization for full automation
Result: 100% automated inspection system with minimal intervention.
Results
- Fully automated vision inspection system deployed
- Met all GM quality standards through PPAP
- Effective collaboration across Ascension, ATS, MTQ4, and GM teams
Tools used during commissioning:
Tools and Technologies Employed
- Matrox Design Assistant
- Keyence IX-Navigator
- Studio 5000 (Allen Bradley PLC)
- Siemens TIA Portal
- Windows Networking