Slalom, a global consulting firm that helps organizations solve complex challenges through strategy, technology, and people-centred design, partnered with a leading railway manufacturer to improve how quality inspections are performed on the factory floor.
The client had relied on manual inspection processes that were labour-intensive, prone to inconsistency, and sometimes posed safety risks to workers. Slalom developed a new system using autonomous, four-legged robots equipped with AI to carry out inspections across the factory environment.
The robots replaced routine human inspections with automated scans that provided real-time insights into product quality. By moving freely through the plant, they were able to access areas that are difficult for people to reach and deliver consistent, high-fidelity inspection data. The system helped identify quality issues earlier and reduce delays caused by manual oversight.
The technology behind the solution combined several layers. A private 5G network enabled fast, reliable communication between the robots and factory systems. On-device computing allowed the robots to process data quickly without relying on external servers, and cloud integration supported broader analysis and digital recordkeeping. Software updates and deployments were handled using containerization to ensure consistency across the robot fleet.
The project started with proof-of-concept testing at the client’s research and development lab. After validating the core technologies, Slalom configured the robots for the factory environment, built the necessary digital infrastructure, and delivered training for engineering staff. The training helped factory workers shift from hands-on inspection to managing robotic systems and analyzing inspection results.
One of the key lessons was the importance of involving factory teams early in the process. Their feedback helped shape a solution that was practical, reliable, and aligned with the realities of production work. Slalom also found that automation could improve inspection quality without disrupting existing workflows, especially when supported by clear change management and training.
The client reported significant improvements in inspection speed, accuracy, and traceability. Inspection times were reduced, human error was minimized, and comprehensive digital records replaced paper-based logs. While exact cost savings were not disclosed, the company noted fewer defects, reduced rework, and increased production efficiency.
The project also contributed to workplace safety by reducing the need for employees to enter hazardous areas during routine inspections. According to Slalom, the shift represented a broader cultural change—one where factory teams moved from performing repetitive tasks to working alongside advanced technologies that support smarter, safer production.
This article is part of Innovation+ in the Plus 15, a special editorial series from the Calgary Innovation Peer Forum and Digital Journal that explores how Calgary-based companies are innovating.
