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Line 4 produces gearbox housings. Operators were catching surface defects by eye at the end of the line, which meant defects found late, high rework, and inconsistent calls between shifts. The team put cameras at two stations and trained a model to flag defects in real time.
It runs in production today on four of nine lines. The team is explicit that the first version failed under night-shift lighting and that fixing it cost seven weeks and $41,000, which is covered in clip 07.