Customer: General Motors (CAMI) Role: Machine Vision Control Engineer Via: Ascension Automation Solutions Location: Ingersoll Timeline: Aug 2024 – Apr 2025
The Challenge
EV battery production was ramping fast. Vision systems were a bottleneck.
- Low throughput (~5 packs/shift)
- Fragile inspections leading to frequent downtime
- Operator loading errors
- Maintenance slowed by unclear alarms and HMI flows
Part 1: Maintenance & Factory Integration
Supported existing vision systems on the production floor — troubleshooting, optimizing, and connecting systems to factory infrastructure.
Key tasks:
- Debugged and stabilized inspection logic to reduce false rejects
- Improved PLC alarms and HMI workflows for faster fault isolation
- Connected vision systems to plant network and data logging
Part 2: New Inspection Station Delivery
Designed and delivered a complete engineering kit for a new vision inspection station.
Software prototype for inspection application:
Production validation with parts on test background:
Operator loader station before camera installation:
Design: CAD layout for camera placement, lighting, and cable routing
Kit included:
- Cameras & lenses
- Lighting
- Mechanical fixtures & mounts
- Cables, routing, and accessories
After: Final station installed and running on production floor
Results
- Throughput increased from 5 → 120 packs per shift (24x improvement)
- Fewer false stops and recoveries
- Maintenance teams diagnosed issues faster
- Line reliability improved during high-volume production
Tools and Technologies Employed
- Machine Vision Systems
- PLC & HMI Integration
- Engineering Kit Design
- Plant Documentation & Handoff