Driving Manufacturing Excellence: Metalsa’s Partnership with Rhombus & Responsive Technology Partners

Global Manufacturing Leader, Complex Operational Environment

As a global leader in chassis and siderail manufacturing for light and commercial vehicles, Metalsa has built a 60-year legacy of operational excellence. Their Roanoke, Virginia facility spans 700,000 square feet and employs 540 people, operating in a complex environment where safety and quality are paramount priorities. The facility handles high-energy laser cutting, welding, and automated robotic systems—all of which require careful monitoring and precise control to maintain both worker safety and production quality.

Critical Visibility Challenges

For a facility where precision and safety are paramount, Metalsa's previous security infrastructure posed significant challenges. With just nine low-resolution cameras, the system left critical operations virtually blind. The challenges were particularly acute in automated manufacturing cells, where robots perform precision cutting and welding. These areas, strictly prohibited to personnel during operation, required frequent manual inspections that put production output at risk.

The visibility gaps extended throughout the facility. Previous attempts to install cameras in robotic cells had failed, with equipment unable to withstand the intense electromagnetic pulses and welding light. Quality inspection points operated without adequate surveillance, allowing material defects to slip through early production stages. Parking lots, delivery zones, and spaces requiring specific PPE compliance lacked proper monitoring, making safety enforcement and incident documentation difficult for staff.

Metalsa, with its deep commitment to employee safety and production quality, knew they needed more than just a camera system—they needed a robust solution engineered to thrive in their harsh industrial environment.

Finding the Right IT Services Partner

When routine server maintenance triggered a factory-wide crisis, Metalsa reached out to Responsive Technology Partners. Living up to their name, Don Daniel and his team at Responsive Technology Partners had a specialist on-site within 90 minutes and restored full operations in under three hours. "We have never worked with another service provider since then because of how good a job they do," notes Chris Lewis, Metalsa IT Specialist. This laid the foundation for addressing Metalsa's broader technology needs, including their surveillance challenges. When Responsive Technology Partners recommended Rhombus, demoing cutting-edge AI and cameras that were IK10 impact resistant and built to withstand harsh manufacturing environments, Metalsa knew they were in store for a game-changing solution.

The Rhombus Revolution

What began as a 52-camera deployment quickly grew to over 120 cameras as teams recognized the system's value. At the core of the solution are Rhombus R200 and R400 dome cameras, which provide clear visibility in high-intensity welding environments. The specialized domes effectively shield against intense light and particulates. The facility strategically placed R360 cameras throughout high-traffic areas, enabling comprehensive monitoring of rail movement and employee activity. For outdoor areas requiring detailed observation, high-resolution R510 cameras ensure precision quality amidst the elements. The entire system is enhanced by AI-powered capabilities, including intelligent motion detection and license plate recognition, all managed through a cloud-based console that enables easy access and sharing of critical footage.

Maximizing ROI: Slashing Scrap & Downtime

Quality Control & Vendor Accountability:

By installing four cameras at a rail inspection station, Metalsa greatly increased the efficiency of the Quality Assurance engineers. Because they were able to use the camera controls to pause, advance frame by frame, and inspect each rail for defects, it has led to a much faster analysis of any items found to be defective. This has allowed Metalsa to work with vendors to prevent defective products, but also saved the Quality Assurance department 80 labor-hours per week for the department.

Overall Equipment Effectiveness:

Having successfully deployed AI-powered dome cameras in over 40 manufacturing cells, Metalsa can now safely monitor robotic operations without endangering employees. Prior to Rhombus, teams would have to randomly enter hazardous zones to recalibrate equipment, hoping to catch issues before they led to costly mistakes. When robots experienced "overtravel" incidents—deviating from their programmed paths—the resulting damage and defective products often went undetected until final inspection.

“For each incident, the team would have to go in and figure out what happened, but with the Rhombus cameras, they can see exactly what caused it. It saves us a lot of time and money by having that information”. Darius Liptrap

Employee Upskilling & Safety:

Rhombus has transformed Metalsa's approach to employee training and workplace safety through powerful video analytics. The team has created over 350 dedicated training clips using the Rhombus Console, enabling targeted education on complex and high-stakes protocols. This video library serves as a dynamic training tool, turning real workplace scenarios into valuable learning opportunities.

A recent example demonstrates this system's impact: After capturing footage of a forklift incident in a tight space, the team quickly implemented two solutions—enhancing driver training programs and installing protective plates to prevent future damage. This proactive response would have been impossible with their legacy surveillance system, which provided no visibility into incident root causes or learning opportunities.

The Rhombus Console has also revolutionized the IT team's incident investigation process, speeding up investigations by over 90%. Advanced features like intelligent motion detection and precise event filtering have transformed what was once a six-hour review process into a task that takes just minutes. As IT Team Member Darius Liptrap explains, "I like how the timeline puts a box and you can go right to the event and see footage direction without scrolling through all the video.”

Enhanced Perimeter Security and Logistics:

The AI-powered license plate recognition system serves dual purposes—tracking shipments for the logistics team while enhancing facility security. The shipping department uses this capability to verify truck arrivals and departures, ensuring accurate and timely deliveries, while security teams maintain a detailed record of all vehicles on premises.

Fueling the Future with AI

Looking to the future, Metalsa is expanding its operational excellence through a new pilot program that combines Rhombus's technology with RoboFlow, a computer vision development platform. This initiative uses AI-powered real-time monitoring to track rail positions and manufacturing progress, with the aspiration of achieving 99.9% accuracy in rail tracking.

Unlike other cloud-based solutions, Rhombus offers a fully open API platform. This gives Metalsa a competitive edge by enabling rapid deployment of new solutions and seamless integration of emerging technologies.

Conclusion

Metalsa's partnership with Rhombus has revolutionized end-to-end capabilities across their complex manufacturing environment. The deployment of ruggedized, AI-powered cameras capable of withstanding harsh industrial conditions has transformed not only security operations but also quality control, safety compliance, and operational efficiency. By adopting Rhombus, Metalsa has established a scalable, proactive monitoring system that delivers measurable improvements in manufacturing quality while reducing costs. Looking ahead, Metalsa continues to pioneer new applications of the technology, as demonstrated by their RoboFlow integration pilot, setting new standards for smart manufacturing surveillance.