Defect Prediction in Spot Welding

Use Case

Predict defects in spot welding using machine data and AI

MindSphere enables defect prediction in spot welding techniques commonly used by automotive manufacturers. Utilizing advanced analytics to examine process data from your lines, defect prediction and analysis is improved to help your line operators quickly address defects within the production cycle.

Many automotive companies leverage spot welding in manufacturing processes due to their speed and relatively low cost. Due to the high number of welds taking place, it is difficult to manually inspect and detect flaws across all of the spot welds being made. 

Supported Industries

We have a solution

Predictive modeling, real time AI 

This solution use case, provided by Tech Mahindra on the MindSphere® platform, enables rapid response to challenges with spot welding based on machine data that would otherwise not be easily noticed by an operator. Actionable alerts and instructions are provided to the operator to address potential flaws while the part is in the most cost-effective place to address the defect.

This detection process reduces rework costs to the manufacturer and improves product quality by helping detect potential flaws before they leave the factory.

Spot welding is a very economical approach to automotive manufacturing, providing potential defects can be caught early. With a 95% first time through success ratio, hidden rework costs are minimized and quality is improved.


  • Artificial intelligence applied to real time machine process data. Monitored process parameters locate potential failure points. 
  • Output data is actionable and easy to understand. Line operators can quickly take action. 
  • Reporting data available to plant management, R&D, Quality operations.
  •  Integration with PLM, ERP, MES systems


  • Predict spot welding defects in real time using machine process data
  • Achieve spot welding success ratios of better than 95% first time through 
  • Allow line operators to quickly address defects in process, minimizing later inspection time and rework
  • Raise customer satisfaction by reducing product defects that reach customers

How it works

Learn more about the applications and services that power this solution. 

Tech Mahindra Professional Services

Tech Mahindra offers a range of professional services to deploy this solution, depending on your needs, and accelerate your digital transformation. Services may include: consulting, implementation, integration, customization and training.


MindAccess IoT Value Plan and MindServices

MindAccess™ IoT Value Plan connects your assets and uses MindSphere applications to leverage your data.

MindService® offers training and professional services to support the development and implementation of your MindSphere solution.

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