Efficiency Gains
Achieved a 45% reduction in coating rework within just 6 weeks of implementing the solution.
How CHS Slashed Coating Rework by 45% Using intelliSPEC’s AI-Driven Workflow
For CHS’s field coating team, missed DFTs, duplicate inspections, and rework were eating up budgets and morale. By switching to IntelliSpec’s Fireproofing & Coating AI module, they streamlined QA checks, digitized all forms, and empowered inspectors with AI-driven defect tagging — cutting rework nearly in half.
“We had no visibility into who painted what, when, and whether it passed DFT — especially with third-party contractors rotating in and out,” said Ravi T., Coating Superintendent.
The Problem
Before IntelliSpec, coating inspections relied on paper logs and manual micrometer readings. With multiple crews and subcontractors working in shifts, CHS faced:
- Inconsistent DFT documentation
- Lack of traceability on coatings
- Delays in touch-up approvals
- Unnecessary rework when QA data went missing
The Solution
CHS implemented intelliSPEC’s Fireproofing & Coating AI Module, using:
- Digital Coating Forms with offline syncing.
- AI-driven image capture and DFT tagging.
- GIS-based mapping of coated zones.
- Live dashboard showing pass/fail rates, rework zones, and coating thickness logs.
Inspectors used ruggedized tablets to capture before/after photos, run AI-assisted DFT checks, and escalate failed spots immediately to the touch-up team. Each coating record was auto-linked to asset tags and time-stamped.
The Impact
The first 6 weeks saw a dramatic shift:
- Field QA times dropped
- All parties operated from the same data
- Supervisors finally had traceable QA history by asset and crew
- Rework dropped 45% in 45 days
“For the first time, I knew exactly where the failures were — and why. That changed everything,” said Ravi.”
Key Results & Achievements
Measurable outcomes and achievements demonstrating the transformative impact and value realized from the intelliSPEC implementation.
Data Integrity
Ensured 100% digital QA log coverage, eliminating manual errors and data loss across all sites.
Inspection Speed
Enabled 30% faster DFT validation, significantly speeding up quality checks and sign-offs.
Full Traceability
Provided full traceability for every job by zone, crew, and asset, meeting strict audit requirements.
Platform Adoption
Facilitated easy adoption across the entire ecosystem: “One platform for everyone — even third-party contractors.”
Operational Improvement
Streamlining inspection workflows to drive operational excellence across all facility maintenance cycles.
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