Nissan has integrated artificial intelligence (AI) into its vehicle production process to improve the detection of paint imperfections. This move has enhanced Nissan’s ability to catch flaws in its paint jobs, with the company reporting a 7% improvement in defect detection thanks to the Nissan AI Paint system.
The automaker implemented the AI-based AUTIS Surface Verification System around three years ago at its Smyrna, Tennessee, assembly plant. The Nissan AI Paint system uses high-resolution cameras that capture 15,000 images of each car as it exits the paint booth. These images are then analyzed by AI software to identify any possible paint defects.
Travis Fritsche, a Nissan paint process engineer, explained that while human inspectors can detect 85% to 95% of paint flaws, the Nissan AI Paint system can identify over 98%. Despite the advanced technology, technicians are still crucial in verifying the defects flagged by the AI, using monitors and wrist-worn smartphones to confirm and classify potential issues. Nissan mentioned that the AI system not only eases the strain on human inspectors but also frees up more time to fix any paint-related problems.
Nissan’s new model paint engineer, Rod Lynch, emphasized that technicians remain key to validating and categorizing defects. He clarified that the Nissan AI Paint system is meant to support and enhance their work, not replace it.
The company has been automating parts of its paint inspection process for some time. In 1985, Nissan introduced laser-equipped robots that could identify defects as small as 0.3 mm in 45 seconds. Today, the Nissan AI Paint system can detect even smaller flaws, down to 0.2 mm, in less than half the time.
In addition to real-time defect detection, the AI system builds a library of confirmed paint flaws, allowing it to continuously refine its accuracy. This growing database can be used by Nissan engineers to address specific issues with vehicle paint processes, depending on the model or color.
According to Nissan, the Nissan AI Paint system has inspected more than 500,000 vehicles at the Smyrna plant, which has an annual production capacity of over 640,000 units. This advanced paint inspection technology is also in use at Nissan’s plants in Canton, Mississippi, and Aguascalientes, Mexico. Together, these plants produce the majority of Nissan’s current models, including the Altima, Frontier, Kicks, Leaf, Murano, Pathfinder, Rogue, Sentra, and Versa.
While Nissan leads the charge in applying AI to production processes like paint inspection, other automakers are exploring AI integration in different areas. For example, the 2025 Volkswagen Golf includes OpenAI’s ChatGPT in its voice assistant system, with Audi expected to follow. Mercedes-Benz is also moving forward with AI, launching a beta program for ChatGPT in 2023 and introducing an AI-powered user interface at CES earlier this year.
By using Nissan AI Paint technology, the company continues to advance its production quality while ensuring human workers play a vital role in the process.
