The Problem
A 2.4-million-person skills gap (Deloitte & The Manufacturing Institute, 2024), rising volumes, and tightening margins are compressing quality control. Manual inspection delivers just 70–80% detection accuracy — well below the 95–99% threshold achieved by AI vision systems — while fatigue and shift changes introduce systematic inconsistency. Critical manual assembly steps remain invisible to OEE systems: not timed, not logged, and therefore impossible to improve.
