Private 5G Boosts ECU Flashing and Paint Defect Accuracy

Overview

Tech Mahindra partnered with a leading Indian automotive manufacturer to deploy a private 5G network that transformed manufacturing operations. The solution enabled real-time ECU flashing and AI-driven paint defect detection, overcoming Wi-Fi limitations across large yards. With edge analytics and secure connectivity, the manufacturer achieved faster inspections, higher accuracy, and improved operational efficiency at scale.

automotive-manufacturer-thumb

Client Background and Challenges

The manufacturer relied on Wi-Fi–based and manual processes for ECU flashing and paint inspection across distributed yards. Limited coverage, blind spots, and sequential workflows slowed operations and increased error rates. Manual visual inspection missed micron-level paint defects, contributing to quality issues and higher recalls, while rework during ECU flashing significantly impacted productivity.

Our Approach and Solution

Business–Technology Fit and Use Case Prioritization

Established a strong alignment between manufacturing KPIs and private 5G capabilities through 5G4E consulting, identifying ECU flashing, pre-delivery checks, and paint quality inspection as high-impact use cases.

ROI-Led Proof of Concept

Validated the value of private 5G through a structured PoC, comparing legacy Wi Fi and 5G performance across ECU flashing efficiency, defect detection accuracy, scalability, and operational impact, supported by a multi-year cost–benefit assessment.

Private 5G Network Deployment

Deployed an on premises private 5G RAN in partnership with a leading telecom provider, ensuring seamless coverage across yards and production lines while eliminating Wi Fi blind spots and enabling parallel workflows.

Edge Analytics–Powered Quality Inspection

Implemented AI-driven paint quality inspection using high resolution cameras and edge analytics, enabling near real-time defect detection, sub 100 micron accuracy, and VIN-level traceability.

Execution, Enablement, and Scale Readiness

Delivered the solution within a controlled timeline, supported by structured enablement sessions to ensure user adoption and readiness for scaling across multiple yards and manufacturing processes.

Benefits

  • Reduced ECU flashing time from 8 seconds to 2 seconds using private 5G
  • Improved paint defect detection accuracy to over 98%, including sub-100-micron defects
  • Enabled parallel workflows across yards, eliminating Wi-Fi blind spots
  • Enhanced quality assurance, traceability, and production efficiency
  • Ensured secure, on-premises data processing and reliability