Customer: General Motors Role: Machine Vision Commissioning Engineer Via: ATS Corporation / Ascension Automation Solutions Location: Ramos Arizpe, Mexico Timeline: Dec 2023 – Jul 2024
The Project
Part of the ATS launch team tasked with tooling a brand new General Motors EV plant in Mexico from the ground up. Commissioned error-proofing vision inspection systems for EV battery lines, starting at the ATS campus in Cambridge, Ontario for Factory Acceptance Testing, then deploying on-site in Ramos Arizpe.
Factory Acceptance Test (FAT)
Built and validated camera inspection systems before deployment using Matrox cameras with Design Assistant, a flowchart-based tool for programming inspection logic.
On-Site Installation
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 field issues including:
- Cameras restarting randomly due to power instability
- Inspection images failing to save to the camera computer
- Unreliable inspections following program updates
Integrated PLC and HMI systems with stack lights, barcode readers, and torque controllers.
Project Phases
Aligned delivery with GM 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
Commissioned and tuned 100+ 2D and 3D vision systems for EV battery error-proofing, achieving 240 packs per 12-hour throughput.
Tools and Technologies
- Matrox Design Assistant
- Keyence IX-Navigator
- Studio 5000 (Allen Bradley PLC)
- Siemens TIA Portal