Case study — AI Application2025

VisionQC

Catching what the eye misses

A computer vision inspection system that checks every part coming off a production line, explains why it flagged something, and sends only the genuinely uncertain cases to a person.

Industry
Manufacturing, Industrial
Year
2025
Screens
09
VisionQC live camera view with model-drawn defect boxes, station status and per-part detections

Overview

About the project

VisionQC is a concept product for manufacturers doing visual quality checks by eye, where fatigue and line speed decide how much actually gets inspected. Cameras at each station photograph every part, a model scores it against the defect classes that matter, and the result is written to a part record that follows the item down the line. The design work went into trust and handover: an inspection system that silently rejects good parts destroys more value than the defects it catches, so every detection shows its confidence, anything ambiguous goes to a human queue, and each decision a person makes becomes a labelled example the model learns from.

The challenge

Visual inspection by eye is inconsistent by nature — it varies with shift, lighting and line speed, and it can only ever cover a fraction of output. Automating it introduces a different risk: a confident model that is quietly wrong will reject good stock or pass bad stock at scale, and an operator with no way to see why something was flagged has no basis to trust or overrule it.

Our solution

We designed around the confidence score rather than hiding it. The live view draws the model's own detection boxes over the camera feed with a confidence figure on each, so an operator sees exactly what was found and where. Anything below the threshold never reaches an automatic reject — it goes to a review queue that shows the flagged region, the model's reasoning and how similar past cases were decided. Those human decisions feed back as training examples, and new model versions run in trial alongside the live one, scoring the same parts without acting on them until the results hold up.

What we built

  1. 01Live defect detectionDetection boxes drawn over the camera feed with per-finding confidence.
  2. 02Confidence thresholdsUncertain calls routed to a person instead of an automatic reject.
  3. 03Human review queueFlagged regions, model reasoning and similar past decisions in one view.
  4. 04Part historyEvery part keeps the images and checks from each station it passed.
  5. 05Yield dashboardsFirst-pass yield, defect mix and line comparison over time.
  6. 06Defect paretoCauses ranked and linked back to the images they came from.
  7. 07Model versioningNew versions trialled alongside the live one before promotion.
  8. 08Feedback training loopReviewer decisions become labelled examples for the next version.
  9. 09Station monitoringCamera health, lighting and trigger status across every line.

Desktop

Where the product doesits heaviest work.

The full-width interface, screen by screen.

VisionQC quality dashboard with yield by hour, defect mix, pareto and line status
Fig. 01 — Quality dashboard
VisionQC human review queue showing flagged parts, model confidence and decision actions
Fig. 02 — Review queue
VisionQC model versions, confusion matrix, training data mix and accuracy over releases
Fig. 03 — Models
VisionQC line layout with station status, camera health and alerts
Fig. 04 — Stations

Mobile

Rebuilt for onehand.

The same information hierarchy, rebuilt for a screen you hold in one hand.

VisionQC mobile production overview with first-pass yield and per-line status
01 — Production
VisionQC mobile alert feed with captured part images and actions
02 — Alerts
VisionQC mobile defect detail showing the captured part image, the model's confidence and the reason it was flagged
03 — Defect detail
VisionQC mobile shift report showing parts inspected, defect rate by line and the most common defect types
04 — Shift report

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