Case study
Fewer quality defects with AI that helps inspectors
A manufacturer used AI to help floor teams spot defects faster, while senior inspectors stayed in charge of every final decision.
- Fewer late defects (pilot products)
- 38%
- Review time per item
- Under 2 seconds
- Time to first pilot
- 10 weeks
Quality results changed from shift to shift. Experienced inspectors knew what to look for, but newer operators did not. Defects often showed up too late on the line.
What we built
The tool works inside the plant’s existing systems. Suggestions show up in context. Operators confirm or override. Every override becomes training signal for the next improvement.
People stay in control. Access rules, audit logs, and confidence thresholds were built in from the start, not added later.
Why it worked
The win came from clear ownership and a narrow first use case, not from chasing a perfect model. We defined which defects mattered, who owns decisions, and how updates get approved before they go live.
Results
Faster inspection on high-volume products
Fewer late defects on the issues we targeted
A clear process to check AI quality before each update
Related work & services
service
AI Product Engineering
Design and ship AI products your teams will adopt, built like real software.
service
System Integration
Wire AI into ERP, CRM, and the tools people already use every day.
industry
Manufacturing
AI systems for throughput, quality, planning, and maintenance, designed for plant reality, not lab demos.