SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE

THE AUTOMOTIVE CHAPTER

Automotive is our home ground.

Based in Gurugram, at the heart of India's automotive belt, we work with Tier 1 press and weld suppliers to the country's largest carmaker, and help OEMs and suppliers check every part and variant at line speed, from the press shop to the dispatch dock.

EXPECTED IMPACT ACROSS THE PLANTTypical ranges from comparable deployments; results vary by site

70 to 90%

fewer customer escapes

100%

of parts, at line speed

60 to 80%

faster new-part set-up

20 to 40%

less unplanned downtime

Across the whole value chain

Press shopP17

Weld nuts, studs and pierced holes, panel surfaces, OK marking

Body in whiteP17

Spot and arc welds, weld cells, sealant beads, gap and flush

Paint shopP19

Dirt, craters, runs, orange peel, gloss and coating coverage

Final assemblyP19

Clips, connectors, harnesses, trim, wheels, VIN and labels

PowertrainP21

Engines, pistons, rods, gears, bearings, seals and fasteners

EV and batteryP23

Cells, busbar welds, modules, packs and thermal checks

Tyres, rubber, plasticsP23

Tyres, gaskets, hoses, moulded parts and lamps

ElectronicsP23

PCBs, ECUs, ADAS sensors, harnesses and pins

Plant and logisticsP25

Bins, safety, QC data, traceability, twins and OT security

One stack across the plant

Wtr.Inspect

Inside the machine: CAD-driven inspection in new or existing machines

Engineered Systems

The complete inspection machine, designed, built and commissioned

Wtr.Scene

The plant's virtual twin: safety, flow and live quality boards

WtrDB and Wtrospai

Behind the scenes: traceability graphs, QC data and back-office automation

Security and Trust

Around it all: TISAX readiness, IEC 62443 OT security and supplier assurance

WHO WE SERVE Carmakers and OEMs Tier 1 and Tier 2 suppliers Two-wheeler makers EV and battery makers Tyre makers SPM builders

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE · HOW WE DELIVER

HOW WE DELIVER

From the first plant walk to a line that checks itself.

We work in short, provable steps on your own parts and cameras, and stay for every model year.

THE JOURNEY

How an automotive project runs

Each step ends with something you can see working, so decisions are made on evidence from your own line.

EXPECTED 30 to 50% faster commissioning, simulated first

COVERAGE

One stack across the plant

Products and services cover the whole value chain, so data from the press shop is still useful at the dispatch dock.

EXPECTED 80 to 90% faster recall trace, press to dock

WHAT SETS OUR DELIVERY APART

Close to the plants we serve

A Gurugram team in the heart of the automotive belt

Takt time first

Every design starts from cycle time, variants and people

Here for every model year

New variants and changes handled under support

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE

AUTOMOTIVE USE CASES · 1 OF 5

Press shop and body in white.

Where our work began. Pressed and welded parts arrive in families with many variants, loose on a belt, under shifting light. We check them from their CAD, without part-specific fixtures.

PRESS SHOP AND SHEET METALEXPECTED IMPACT UNDER EACH ITEM · TYPICAL RANGES

Weld nut and stud verification

80 to 95% fewer nut and stud escapes

Presence, count, position and thread condition of nuts and studs on brackets and panels. Delivered on our ScanLine SPM8 machine.

Pierced hole checks

100% of holes checked, every part

Every hole present, in position and to size, in the same pass as welded features

Part family changeover

60 to 80% faster new-part set-up

Automatic part identification from CAD so one machine runs the whole family

Panel surface defects

70 to 90% fewer surface escapes

Splits, wrinkles, necking, dents, scratches and burrs on outer and inner panels

Edge and trim quality

50 to 70% less manual checking

Trim line accuracy, edge burrs and flange condition after cutting and hemming

Coil and blank surface

20 to 30% less scrap after the press

Coating gaps, thin spots, rust and scratches caught before the press, at line speed

Inspection marking gantries

100% of OK parts stamped

Stamp gantries that mark each passed part "OK", tied to the inspection verdict

BODY IN WHITE AND WELDING

Spot weld presence and count

80 to 95% fewer missing-weld escapes

Missing or extra welds, weld position, spatter and burn-through on assemblies

Weld and joint quality

70 to 90% fewer joint defects shipped

Surface cracks, incomplete welds, porosity and misalignment on arc and MIG welds

Robot weld cell monitoring

20 to 40% less unplanned downtime

Tip dress events, cap condition, throat occupancy, air blow verification and anomalies

Sealant and adhesive beads

70 to 90% fewer bead escapes

Bead presence, continuity, width and position on hems, seams and joints

Gap and flush measurement

70 to 90% less measuring time

Doors, hoods, tailgates and panels measured for consistent fit across variants

Sub-assembly completeness

80 to 95% fewer missing parts

Brackets, reinforcements and fasteners present and correctly oriented before joining

Weld line quality dashboards

40 to 60% faster response to drift

Robotic weld sub-assembly results linked to the backend and shown live on LED screens

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE · HOW IT WORKS

PRESS SHOP AND BODY IN WHITE · HOW IT WORKS

How we see every nut, panel and weld.

Each item in our inspection portfolio rests on a few proven setups. Here is how they work.

1 · PRESS SHOP

Weld nut, stud and hole checks

Every nut, stud and pierced hole is compared with the part CAD in one pass, so a whole part family runs on one machine without fixtures.

EXPECTED 80 to 95% fewer nut and stud escapes

2 · PRESS SHOP

Panel surface defects

Stripes of light reflected from the panel bend wherever there is a dent, split or wrinkle, and cameras capture the whole surface at line speed.

EXPECTED 70 to 90% fewer surface escapes

3 · BODY IN WHITE

Spot welds and sealant beads

A robot-mounted 3D profiler follows the seam, measuring bead presence, width and position, and counting spot welds against the weld plan.

EXPECTED 80 to 95% fewer missing-weld escapes

4 · BODY IN WHITE

Gap and flush

A laser line profiler measures the gap between panels and the step between their surfaces at every checkpoint, for every variant.

EXPECTED 70 to 90% less time than CMM sampling

WHAT SETS OUR DELIVERY APART

One machine, whole family

Part identity from CAD switches recipes on its own

Results on the line

OK stamps, reject gates and live LED boards

Evidence that lasts

Every image and verdict kept for traceability

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE

AUTOMOTIVE USE CASES · 2 OF 5

Paint shop, final assembly and traceability.

PAINT AND SURFACEEXPECTED IMPACT UNDER EACH ITEM · TYPICAL RANGES

Paint defect detection

20 to 30% less paint rework

Dirt and dust inclusions, craters, runs, sags, pinholes and micro-scratches under reflective light

Finish and appearance

50 to 70% less manual audit time

Orange peel, uneven gloss and colour mismatch between panels and bumpers

Coating coverage

100% of bodies checked

E-coat, primer, sealer and underbody coating applied where they should be

Dents and handling damage

70 to 90% fewer customer escapes

Dents and dings from transfer and handling, found before they reach the customer

Defect mapping to the body

30 to 50% faster repair

Each finding placed on the body model so repair teams go straight to it

FINAL ASSEMBLY AND TRIM

Clips, connectors and fitment

80 to 95% fewer missing clips

Presence, absence and misfit of injector clips, connectors, fasteners and brackets

Torque marks and fasteners

80 to 95% fewer fastener escapes

Torque stripes, washers and bolts confirmed at critical joints

Harness and hose routing

70 to 90% fewer routing faults

Wiring and hoses routed, clipped and connected as designed

ADAS sensors and electronics

80 to 95% fewer fitment escapes

Camera, radar and sensor placement and connector fitment for advanced driver assistance

Interior, dashboard and trim

50 to 70% less manual inspection

Stitching, colour consistency, surface uniformity and component assembly in cabins

Glass and lamps

70 to 90% fewer customer escapes

Chips, scratches, bubbles and seal condition on glazing, headlamps and tail lamps

Wheels and undercarriage

80 to 95% fewer wrong fitments

Correct wheel and tyre, valve position, brake and suspension parts present and aligned

Variant verification

80 to 95% fewer wrong variants

Fitted parts matched against the build sheet by barcode or QR, for every variant

LABELS, CODES AND TRACEABILITY

OCR and OCV on components

50 to 70% less manual checking

Printed, etched, embossed and dot-peen marks read and verified on any surface

VIN, engine and label checks

80 to 95% fewer label errors

VIN plates, engine numbers, barcodes and labels present, legible and correct

Audit-ready inspection records

80 to 90% faster recall trace

Image, time, batch and verdict linked to the VIN or part number for full genealogy

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE · HOW IT WORKS

PAINT, ASSEMBLY AND TRACEABILITY · HOW IT WORKS

From the paint tunnel to the VIN record.

Paint, final assembly and traceability each need their own setup. Here is how each works.

1 · PAINT AND SURFACE

Paint inspection tunnel

Lights and cameras around the body catch inclusions, craters, runs and orange peel under reflective light. Each finding is placed on the body model, so the repair team goes straight to it.

EXPECTED 20 to 30% less paint rework

2 · FINAL ASSEMBLY

Assembly and variant checks

The build sheet sets the rules for each vehicle. Cameras confirm every clip, connector and torque mark for that exact variant.

EXPECTED 80 to 95% fewer wrong or missing fitments

3 · LABELS AND TRACEABILITY

Codes, VIN and genealogy

Marks are read and verified on any surface, then linked with images, station and time in a WtrDB graph for a full genealogy.

EXPECTED 80 to 90% faster recall trace

WHAT SETS OUR DELIVERY APART

Every variant, every vehicle

Rules follow the build sheet automatically

Repair goes straight to it

Findings mapped onto the body or part model

Audit-ready by default

Image, time, batch and verdict kept per VIN

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE

AUTOMOTIVE USE CASES · 3 OF 5

Powertrain and precision components.

ENGINEEXPECTED IMPACT UNDER EACH ITEM · TYPICAL RANGES

Engine assembly

80 to 95% fewer assembly escapes

Gear alignment, shaft position, seal integrity, bearing fit and sensor installation

Borescope inspection

50 to 70% less manual inspection

Cylinder bores, ports and internal cavities checked for porosity, scoring and debris

Crankcase sealant

70 to 90% fewer leak escapes

Sealant bead continuity, breaks, width and position before closing

Pistons

70 to 90% fewer defect escapes

Skirt scuffing, crown cracks, ring groove wear, pitting and clogged oil holes

Connecting rods

50 to 70% less manual inspection

Fine surface defects, inspected by robot across every face

Gaskets and seals

70 to 90% fewer seal escapes

Cuts, deformation, missing beads, flash and contamination

Spark plugs

100% checked at line speed

360 degree checks of insulator, electrode gap, threads and shell

Oil filters and starters

80 to 95% fewer variant mix-ups

Filter crimping, dents, seals and print; starter switch caulking across variants

Castings and machining

20 to 30% less machining scrap

Block and head porosity, blowholes, chamfers, threads, burrs and machined dimensions

TRANSMISSION AND DRIVELINE

Gears and shafts

70 to 90% fewer defect escapes

Tooth profile, nicks, burrs, splines and heat treatment marks

Sprockets

50 to 70% less manual inspection

Tooth deviations, cracks, burrs and wear for reliable drivetrains

Bearings

70 to 90% fewer bearing escapes

Grinding marks, cracks, dents, raceway condition, dimensions and ball count

CHASSIS, BRAKES AND FASTENERS

Brake pads

70 to 90% fewer defect escapes

Cracks, edge chipping, rust, uneven thickness, delamination and material flash

Ball rods and joints

50 to 70% less manual inspection

Scratches, dents, rust, thread and coating defects on steering and suspension parts

Fasteners

80 to 95% fewer fastener mix-ups

360 degree thread, head, length, pitch and orientation checks on bolts, nuts and rivets

Springs and suspension

80 to 95% fewer wrong variants

Coil count, coating, cracks and correct part for each variant

Small, repeatable parts suit Wtr.Inspect in an existing machine, or a compact station from Engineered Systems.

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE · HOW IT WORKS

POWERTRAIN AND PRECISION COMPONENTS · HOW IT WORKS

Every face of every precision part.

Defects hide in bores, around circumferences and under heads. Three setups see them all.

1 · ENGINE

Engine internals

A robot guides a borescope into each bore and cavity, so porosity, scoring and debris are found inside the part, alongside sealant bead checks before closing.

EXPECTED 50 to 70% less manual inspection effort

2 · TRANSMISSION AND DRIVELINE

Gears and bearings, all round

The part turns in front of a line-scan camera, which unwraps its whole circumference into one image where a nick or crack stands out.

EXPECTED 70 to 90% fewer customer escapes

3 · CHASSIS, BRAKES AND FASTENERS

Fasteners, pads and small parts

Small parts are seen from every side at once and checked against their reference at full rate.

EXPECTED 100% of parts checked on every side

WHAT SETS OUR DELIVERY APART

Inside the part, too

Borescopes reach bores, ports and cavities

All the way round

Rotation and camera rings leave no blind side

Fits your machines

Wtr.Inspect in an existing station, or a compact new one

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE

AUTOMOTIVE USE CASES · 4 OF 5

EV, tyres, plastics and electronics.

EV AND BATTERYEXPECTED IMPACT UNDER EACH ITEM · TYPICAL RANGES

Cell surface

70 to 90% fewer cell escapes

Dents, scratches, swelling, leakage and contamination on cylindrical, prismatic and pouch cells

Busbar and cell welds

70 to 90% fewer weld escapes

Laser and ultrasonic weld presence, position, spatter and incomplete fusion

Module and pack assembly

80 to 95% fewer missing parts

Busbars, connectors, casings, insulation and fasteners present and correctly fitted

Thermal checks

100% of cells screened

Thermal cameras flag hot spots and uneven heating during formation and testing

Cell and pack traceability

80 to 90% faster recall trace

Cell IDs and labels read and linked to the pack, module and inspection images

TYRES AND RUBBER

Tyre defects

70 to 90% fewer defect escapes

Micro-cracks, bead misalignment, foreign particles and tread or sidewall flaws after curing

Sidewall code reading

50 to 70% less manual reading

Moulded size, date and serial codes read on black rubber

Mould and process insight

30 to 50% faster root cause

Defects linked to individual moulds, presses and shifts so causes are found quickly

Hoses and rubber parts

50 to 70% less manual inspection

Cuts, bubbles, flash and dimensional checks on hoses, grommets and seals

PLASTICS AND MOULDED PARTS

Injection moulded parts

70 to 90% fewer defect escapes

Flash, short shots, sink marks, warpage, weld lines, flow lines, cracks and crazing

Bumpers and exterior trim

20 to 30% less rework

Paint, texture and fitment checks on fascias, grilles and mouldings

AUTOMOTIVE ELECTRONICS

PCB assembly

70 to 90% fewer solder escapes

Missing, shifted or reversed components, solder bridges and insufficient solder

Connectors and pins

80 to 95% fewer pin escapes

Bent, missing or recessed pins and housing damage before final assembly

Wire harnesses

80 to 95% fewer crimp escapes

Wire colour sequence, crimp quality, terminal seating and tape positions

ECUs, displays and sensors

70 to 90% fewer defect escapes

Housing, label and screen defects on control units, clusters and sensor modules

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE · HOW IT WORKS

EV, TYRES, PLASTICS AND ELECTRONICS · HOW IT WORKS

Four materials, four ways of seeing.

Cells, rubber, glossy plastic and tiny electronics each defeat ordinary cameras. Here is how.

1 · EV AND BATTERY

Busbar welds and hot spots

A 3D profiler checks every weld, and a thermal camera flags uneven heating in formation.

EXPECTED 70 to 90% fewer weld escapes

2 · TYRES AND RUBBER

Tyre sidewalls and codes

Codes are read under low-angle light, and each flaw is traced to its mould and press.

EXPECTED 30 to 50% faster root cause

3 · PLASTICS AND MOULDED PARTS

Moulded parts

Light from many angles at once lifts shallow sink marks, flow lines and flash that a single light would hide.

EXPECTED 70 to 90% fewer customer escapes

4 · AUTOMOTIVE ELECTRONICS

PCBs, pins and harnesses

Every component is checked for presence, position and polarity, and every harness for wire colour sequence and terminal seating.

EXPECTED 70 to 90% fewer solder and pin escapes

WHAT SETS OUR DELIVERY APART

Right light for the job

Profilers, thermal, line scan and dome lighting

Causes, not just counts

Defects traced to the mould, press, shift or cell

One platform for all four

The same software and records across every line

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE

AUTOMOTIVE USE CASES · 5 OF 5

Plant operations, logistics and data.

Quality lives beyond the inspection station. These projects keep parts, people and information moving safely through the plant and out to the customer.

Returnable bin tracking

TIER 1 AUTOMOTIVE SUPPLIER

UHF RFID tags on metal stillages, fixed read points and a CCTV camera at the loading dock, connected to the GPRS tracking already fitted to the client's trucks, so missing bins can be found in the supplier to OEM loop.

3,000

Bins at the first plant

30,000+

Bins in the national programme

30 to 50%

Fewer lost bins, expected

Quality operations data lake

QC results from tablets and machines unified on a central server with automated reports, built on OpenSearch

EXPECTED 60 to 80% less QC report preparation

Live quality boards

Machine and line quality shown on LED screens outside QC rooms and on the shop floor

EXPECTED 40 to 60% faster response to drift

Part genealogy graph

Coil, part, machine, operator, inspection and VIN linked in WtrDB for instant recall answers

EXPECTED 80 to 90% faster recall trace

Plant safety from cameras and sensors

PPE, gangways, restricted zones and near misses, with Wtr.Scene and new safety sensors (Explore)

EXPECTED 40 to 60% fewer PPE violations

Dispatch and loading checks

Part counts, packing, labels and load verification at the dock before trucks leave

EXPECTED 80 to 95% fewer dispatch errors

Predictive maintenance

Sensor and video signals from presses, robots and conveyors used to spot failures early

EXPECTED 20 to 40% less unplanned downtime

Animated line twins

Whole assembly lines built in 3D in Wtr.Scene and exported as polished videos for customers

EXPECTED 70 to 80% less time making videos

Back-office automation

Logistics reconciliation, supplier documents and stock checks automated with Wtrospai

EXPECTED 50 to 70% less reconciliation effort

Supplier quality and DPDP

Supplier assurance, data protection readiness and staff awareness for plant teams

EXPECTED 40 to 60% less audit effort

OT and TISAX security

IEC 62443 assessments, IT and OT segmentation and TISAX readiness, see Explore

EXPECTED 40 to 60% fewer exposed OT paths

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SFTWTRS.AI INDUSTRIAL AI · AUTOMOTIVE · HOW IT WORKS

PLANT OPERATIONS · HOW IT WORKS

Keeping parts, people and data moving.

Quality and safety reach well beyond the inspection station, from the dock to the QC room.

1 · LOGISTICS

Returnable bin tracking

Tagged stillages are read at the dock as they leave and return. Truck GPS shows where they are in between, and overdue bins raise alerts.

EXPECTED 30 to 50% fewer lost bins

2 · QUALITY DATA

Quality data lake and live boards

Light agents on tablets, PCs and machines send results to one server, which produces shift reports and drives LED boards outside the QC room.

EXPECTED 60 to 80% less QC report preparation

3 · TRACEABILITY

Part genealogy graph

Coil, part, machine, operator, inspection and VIN are linked in WtrDB, so a recall question is answered by following the links in seconds.

EXPECTED 80 to 90% faster recall trace

4 · SAFETY

Safety and flow from cameras

Wtr systems read existing CCTV for PPE, blocked gangways and near misses, and Wtr.Scene shows where risk gathers across the plant.

EXPECTED 40 to 60% fewer PPE violations

WHAT SETS OUR DELIVERY APART

Uses what is already there

Existing cameras, tablets and truck trackers

One record of the plant

Logistics, quality and safety data joined up

Built to grow

Start with one dock or one line, then scale plant-wide

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Let's build what comes next.

Tell us what you want to see, understand or protect better.

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