Gap and Flush Inspection AI

Add a real-time fit inspection layer to every unit with vision AI for gap and flush inspection. Built for the operations where one tapering door gap, hood corner sitting proud, or misaligned lamp against the fascia rolls off the line looking finished and lands at the dealership as a complaint, an audit finding, or a buyback risk. Whether you're running automotive body shop and final assembly, appliance door lines, or any product where panels meet in front of the customer, Roboflow extends fit inspection to every unit at line rate, with a per-unit record behind every closure.

Gap and Flush Defect Detection:

• Catch uneven, tapering, and out-of-spec gaps along doors, hoods, liftgates, and fenders on every unit
• Detect proud and sunken panels where flush breaks the surface line the customer's eye follows
• Flag misaligned trim, lamps, badges, and grilles against their mating surfaces

Fit Consistency and Drift:

• Learn what a good unit looks like and flag out-of-family fits the moment one rolls through, even inside nominal limits
• Trend fit by station, shift, and model to catch fixture wear, hemming drift, and hinge-setting issues while they're still adjustments
• Extend coverage to every unit between your gauge and audit checks, so the tenth-unit sample never has to carry the whole shift

Lines, Audits, and Systems Integration:

• Inspect at body shop exit, final assembly, and end-of-line, with imagery attached to every flagged closure
• Route flagged units to fit-finish repair automatically through PLC and MES integration
• Keep per-VIN fit records that support IATF 16949 documentation, launch containment reviews, and customer audits

Bring intelligence to every closure today. Stop fit defects from becoming dealership complaints, audit failures, or rework bays full of finished units.

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More About Gap and Flush Inspection

What is gap and flush inspection with Vision AI?

Gap and flush inspection with vision AI uses computer vision models to inspect panel fit on every unit: the gaps along doors, hoods, liftgates, and fenders, the flush condition where adjacent panels meet, and the alignment of trim, lamps, and badges. Models trained on your actual vehicles or products catch uneven, tapering, and out-of-family fits at line rate, with per-unit records and imagery that support IATF 16949 documentation and fit-finish audit programs.

Can Vision AI catch fit problems on reflective painted panels at line rate?

Painted closures are the hard case: dark metallics swallowing edges, gloss throwing moving reflections as the unit travels, and gap lines that curve through three dimensions. Deep-learning models trained on your actual paint colors, lighting, and line motion learn to read the gap line and surface break through reflection and color, inspect at takt time on every unit, and flag out-of-family fits that a sampled check would statistically miss, with the flagged closure's imagery attached so the repair team sees exactly what the camera saw.

Does gap and flush inspection support IATF 16949 and PPAP?

Yes. Roboflow models can run as documented inspection controls inside your IATF 16949 (automotive quality management) and ISO 9001 processes, with per-VIN fit records, imagery, model version history, and training data lineage that support PPAP submissions, launch containment reviews, and customer audits. Roboflow is the inspection engine; your quality team owns the fit specifications and disposition rules.

Can it integrate with our line PLCs, repair routing, and MES?

Yes. Roboflow Inference exposes a standard API and supports common industrial protocols, so fit events flow into your existing systems: line PLCs from Allen-Bradley and Siemens, SCADA and HMI platforms like Ignition and AVEVA, MES and quality systems, and ERP platforms like SAP, through REST, MQTT, OPC UA, and direct database writes. PLC-level integration routes flagged units to fit-finish repair the moment a closure fails, and every event carries VIN, station, imagery, and disposition, with a full audit trail behind every unit.

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