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How a Growth-Stage Technology Company Built Unit Inspection Where a Technician's New Defect Joins the Catalog

Operations1
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Five-Step AI Workflow with Human Oversight

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Estimates are directional and based on stated assumptions. All names, organizations, and identifying details have been anonymized in accordance with our confidentiality agreements.

The Transformation

How a Growth-Stage Technology Company Built Unit Inspection Where a Technician's New Defect Joins the Catalog

Before
A person used to walk the line each shift checking the cameras by eye.
A person used to pull a sample tray from each pallet and check it by eye.
After
every unit imaged and threaded, the bad frames held
every unit checked, every defect named or sent to the bench
the units the check could not clear, cased and waiting on you
failures watched across the shift, the drift called before the run
the shift reconciled, and what the check should learn
Executive Summary

Every unit that comes off the line, from the moment it crosses the camera to the moment its shift is reconciled. The agents photograph every unit, check every frame, divert the failures, and hand a person only the units no catalog entry can settle, the call to stop a line, and the decision to change what the check catches. Five stations, run as a loop: a defect named at the bench today is in the catalog before tomorrow's first unit crosses the camera.

What Was Broken

A person used to walk the line each shift checking the cameras by eye
The real cost
A person used to pull a sample tray from each pallet and check it by eye.

What We Built

Five stations and 10 subagents. Each subagent carries its own tasks and its own refusal.

A4
Frame Sweep
Capture four frames of every unit crossing the three lines
A3
Camera Watch
Check every camera's focus, light and frame rate each minute
A4
Defect Finder
Scan all four frames of each unit for marks, gaps and misalignments
A3
Verdict Sort
Classify each unit pass, fail or unsure from its measured finds
A1
Case Builder
Draft a one-line recommendation for each held unit: rework, scrap or release
A3
Decision Record
Record each decision with the frames that were on screen when it was made
A4
Trend Track
Track pass and fail counts per line, machine and hour, all shift
A3
Alert Desk
Route each alert to the person the roster puts on that line
A4
Shift Count
Reconcile every imaged unit against a verdict, a bench decision or an open hold
A2
Threshold Proposal
Propose the threshold or catalog change that would have caught each repeated miss

How It Runs

1

Line Capture

Nobody is asked anything here

Agents photograph every unit crossing the three lines, thread each frame onto the unit that was under the lens, and hold any unit whose frames the light ruined. Nothing waits on a person here. A unit with no usable frame is never passed as good; it goes to the hold bench unscored, with its frames attached.

2

Defect Inspection

Nobody is asked anything here

Agents check all four frames of every unit, measure each mark against the tolerance its position allows, name each defect against the catalog, and judge the unit pass, fail or unsure. Nothing waits on a person here. A mark the catalog cannot name is never guessed into a category; the unit goes to the bench marked unsure.

3

Held Unit Review

A person answers here

Agents build the case for each held unit, its frames, its measurement, the nearest catalog matches and what similar units got, then draft a recommendation and wait. This is where a person works. A held unit leaves the bench only with a decision recorded against its frames, and a new defect gets its name from the person who calls it.

4

Drift Watch

A person answers here

Agents track failures across every line, machine and hour, trace each cluster back to the minute it started, and page the person the roster puts on that line with the evidence. This is where a person decides. The agents call the drift, and the person calls the stop, because a stopped line costs the shift.

5

Shift Close

A person answers here

Agents reconcile every imaged unit against a verdict, a bench decision or an open hold, draw where the shift's defects landed, and propose the changes that would have caught each repeated miss. A person accepts or rejects each change. What the check fails a unit for is not something an agent tightens quietly.

Where a Person Decides

Step 3, Held Unit Review. Decide the 11 held units, the cases are laid out. Name the unit 4471 mark if it is a new defect, and the check learns it. no decision, no release.
Step 4, Drift Watch. Answer the Line 2 alert, stop the line or run it to the break. Say if the coil change explains it, and the alert closes with its cause. the line stops on your say, not the agents'.
Step 5, Shift Close. Accept or reject the two proposed changes. Say where the 11:52 unit went, or send somebody to find it. the check never tightens itself quietly.

Operating Model

This changes how work flows through the team.

Role
Responsibility
Held Unit Review owner
Decide the 11 held units, the cases are laid out. Name the unit 4471 mark if it is a new defect, and the check learns it. no decision, no release.
Drift Watch owner
Answer the Line 2 alert, stop the line or run it to the break. Say if the coil change explains it, and the alert closes with its cause. the line stops on your say, not the agents'.
Shift Close owner
Accept or reject the two proposed changes. Say where the 11:52 unit went, or send somebody to find it. the check never tightens itself quietly.
Line Capture, when it goes wrong
Look here only if a camera goes down mid-shift.
Defect Inspection, when it goes wrong
Look here only if a customer reports a defect the check passed.

What Transfers, What Must Be True

What transfers
A person is in the loop wherever a unit's fate, a line's stop, or the check itself is decided. Three stations refuse to proceed on their own, Held Unit Review, Drift Watch and Shift Close, and those are the three a person carries. Everywhere else the agents photograph, check, divert and watch, and reach you only when the call is yours to make.
Held Unit Review stops for a person, and no decision, no release.
Drift Watch stops for a person, and the line stops on your say, not the agents'.
Shift Close stops for a person, and the check never tightens itself quietly.
Every subagent says what it will not do. 10 of them do.
What must be true in your environment
The agent can read the systems your records already live in. This one reads 15.
Somebody owns Held Unit Review and has time for it.
Somebody owns Drift Watch and has time for it.
Somebody owns Shift Close and has time for it.

Failure Modes

What breaks this pattern:

✗ Scoring a unit nobody saw

Without the hold rule, a unit with no usable frame still gets a score. The score comes from nothing, and a bad unit ships with a clean record.

✗ New defects wear old names

Without the bench rule, the agent guesses an unknown mark into the nearest catalog name. A new defect type hides under an old label, and nobody knows it exists until customers do.

✗ Held units leave without answers

Without the recorded decision, a held unit gets released and the reason leaves with the person who released it. Six months later a recall question has no answer.

✗ The agent stops the line

Give the agent the stop button and one false drift call costs the shift. A person can weigh that cost. The agent only sees the numbers.

Directional Outcomes

What the agent counts, and the station that counts it.

These counts are the tallies from one monitored run of the agents. They are not monthly or annual totals.

Units imaged
Counted at Line Capture
410,000
Units that crossed unimaged
Counted at Line Capture
0
Units it sent to the bench unscored
Counted at Line Capture
380
Units checked
Counted at Defect Inspection
410,000
Checked units returned by a customer
Counted at Defect Inspection
0
Units it would not judge, sent to the bench
Counted at Defect Inspection
1,240
Our measurement policy: We do not publish precise ROI without baseline methodology. Every figure above carries its basis.

What Runs Where

Every step names the subagent that does the work, the record it writes, the thing that raises a question for a person, and what it is allowed to touch. This is drawn from the source, not from a diagram somebody kept in sync by hand.

1Line Capture
subagentframe-capture
writesvision/frames/<unit-id>/
raiseshold-unusable-frame
may touchvision/frames/**, vision/held/**, the camera feeds read-only
2Defect Inspection
subagentdefect-inspect
writesvision/verdicts/<unit-id>.json
raisescannot-name-defect
may touchvision/verdicts/**, vision/frames/** read-only
3Held Unit Review
GATE
subagentbench-case
writesbench/cases/<unit-id>.md
raisesawait-your-decision
may touchbench/**, everything else read-only
4Drift Watch
GATE
subagentline-watch
writesalerts/<alert-id>.json
raisesline-stop-call
may touchalerts/**, vision/verdicts/** read-only
5Shift Close
GATE
subagentshift-close
writesrules/proposed/<rule-id>.json, reports/shift-<date>.json
raisesaccept-threshold-change
may touchrules/proposed/**, reports/**, the history read-only

Stack

Every system this agent reads or writes.

System
Read at
Stations
the defect catalog
Defect Inspection
3 of 5
the frame store
Line Capture
3 of 5
the hold bench queue
Held Unit Review
1 of 5
the line controllers
Line Capture
2 of 5
the line diverters
Defect Inspection
1 of 5
the maintenance list
Line Capture
1 of 5
the phone alerts
Drift Watch
1 of 5
the quality dashboard
Shift Close
1 of 5
the rework log
Held Unit Review
2 of 5
the shift record
Shift Close
1 of 5
the shift roster
Drift Watch
1 of 5
the threshold table
Shift Close
1 of 5
the twelve line cameras
Line Capture
1 of 5
the unit record
Defect Inspection
1 of 5
the verdict record
Drift Watch
1 of 5
Next Step

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