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- Preventing a Critical Component Mismatch at a Leading Electric Vehicle Manufacturer
Industry
EV Automotive
Challenge
Traceability, Counterfeit & Tampered Components
Solution
Cybord Visual AI Platform
Background
A leading global electric vehicle (EV) manufacturer renowned for its innovation and scale – relies on high-volume SMT lines to produce safety-critical electronic assemblies. In partnership with the local EMS provider, Cybord’s Visual AI solution was deployed to inspect and analyze every component mounted on the PCBA.
The Challenge:
During a routine inspection on the SMT line, Cybord’s system detected a subtle anomaly on the top-side marking of a commonly used component. It was from a legitimate franchise manufacturer, and at first glance appeared identical to all the other components approved by the OEM. But Cybord flagged the deviation: one small marking – the letter designating the automotive-grade version – was missing.
This component was being used in a vehicle control system and was expected to meet automotive-grade standards, particularly with regard to thermal and environmental resilience.
The Discovery
The alert prompted the manufacturer to investigate. It turned out that the component—although authentic and from the correct vendor—was mistakenly sourced as an industrial-grade variant, not qualified for automotive use. Without Cybord’s inspection, the substitution would have gone unnoticed.
The Impact
Had the mistake gone undetected, thousands of units could have been assembled and shipped with non-compliant components. This would have triggered widespread quality and safety risks, potential recalls, and regulatory consequences.
Thanks to Cybord’s component-level visual AI and real-time detection, the issue was caught early—before a single defective board left the factory
Deployment & Integration
Proactive
Immediate line-wide alert for out-of-spec components
Prevetive Action
Prevented mass contamination of a production batch
Impactful
Protected the EV manufacturer from a potential recall and safety breach
Valuable
Proved the value of top-side visual-AI inspection for subtle anomalies and AVL enforcement
Customer Quote
Cybord gave us the ability to enforce our AVL at the component level, with real-time detection that seamlessly fits into our production flow. It’s a new standard of integrity control for us.
Sr. Engineering Manager
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