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D14OPERATIONS

Quality control vision inspection

Looks at images or video of physical items moving through a production, packing, or fulfillment process, and flags items that fail the firm's quality criteria: damaged packaging, missing components, incorrect labels, manufacturing defects. Sits alongside human QC rather than replacing it: the pattern handles the high-volume routine cases so humans can focus on the genuinely ambiguous ones. Different shape from the other D patterns because it processes images, not text or structured records, and because the kill metrics are different (false negatives let bad product through; false positives slow throughput). Used in light manufacturing, fulfillment, and food production.

WHERE THIS FITS
BUSINESS SHAPES
Product company
VOLUME THRESHOLD
Below 500 items inspected per day a month, the payback rarely earns the build. Patterns this shape reliably pay back at 5,000+.
REQUIREMENTS · 7 REQUIRED

Requirements describe capabilities the pattern needs in your environment, not the vendors you must buy. Any system that fills a requirement satisfies it — that’s what makes the catalog portable across the long tail of SMB tooling.

  1. image_capture_source
    REQUIREDREADstream

    Where images of items come from. Physical setup matters: lighting, angle, consistency.

    DATA SHAPE
    Image or short video clip with item identifier, capture timestamp, line/station identifier.
    COMMONLY FILLED BY
    • camera installed over a production line
    • imaging station integrated with the conveyor system
    • handheld scanner used by inspectors
    • phone-based capture at pack-out stations
  2. defect_taxonomy_and_examples
    REQUIREDREADcorpus

    What 'bad' looks like, specifically. The pattern learns from examples; without enough labeled examples per defect class, it can't be trusted.

    DATA SHAPE
    Per-defect-class: name, description, decision rule, set of labeled positive and negative example images.
    COMMONLY FILLED BY
    • labeled dataset built during the engagement
    • ongoing labeling workflow where QC inspectors add to the dataset
    • structured defect catalog the operations team maintains
  3. item_record_lookup
    REQUIREDREADrequest

    What item is being inspected and what its specifications are. Different items have different inspection criteria.

    DATA SHAPE
    Per-item SKU with inspection specification, packaging requirements, customer-specific variations.
    COMMONLY FILLED BY
    • ERP item master with QC specifications
    • product catalog with inspection criteria
    • customer-specific shipment requirements
  4. inspection_decision_destination
    REQUIREDWRITEevent

    Where pass/fail decisions go. Pass-through for accepted items, divert for rejected items.

    DATA SHAPE
    Decision per item: accept/reject/uncertain, defect class if rejected, confidence score, image stored for review.
    COMMONLY FILLED BY
    • control signal to the production line diverter
    • scan log in the warehouse management system
    • result feed into the operations dashboard
  5. human_qc_review_station
    REQUIREDREAD + WRITErequest

    Where uncertain or borderline cases get human verification. Critical for the cases the pattern doesn't handle confidently.

    DATA SHAPE
    Image with proposed classification, confidence score, comparison to similar cases. Reviewer marks final decision.
    COMMONLY FILLED BY
    • dedicated review station at the QC desk
    • tablet at the inspection point with the review UI
    • remote review queue for off-line review
  6. audit_image_archive
    REQUIREDWRITEcorpus

    Stored images of inspected items for traceability and quality investigations. Particularly important in regulated industries.

    DATA SHAPE
    Image with item identifier, inspection result, timestamp, retention metadata.
    COMMONLY FILLED BY
    • object store with retention policies
    • QC archive in the manufacturing operations system
    • compliance archive for regulated products
  7. model_retraining_loop
    REQUIREDREAD + WRITEbatch

    How human verdicts feed back to improve the pattern. Without this loop, the model can't adapt to new defect types or environmental changes.

    DATA SHAPE
    Reviewed cases with original prediction, human verdict, image, reason for override.
    COMMONLY FILLED BY
    • weekly batch of reviewed cases added to the training set
    • continuous labeling pipeline where each correction feeds back
    • quarterly model retraining process
RUNTIME FLOW · 8 STEPS
  1. 01
    Capture image of item at the inspection point, tagged with item identifier
    image_capture_source
  2. 02
    Look up the item's specification to know what we're inspecting against
    item_record_lookup
  3. 03
    Run image through the inspection model trained on the defect taxonomy
    defect_taxonomy_and_examples
  4. 04
    Classify result: pass / fail-with-class / uncertain
    DECISION Threshold-based; uncertain cases route to human review.
  5. 05
    For pass: signal accept and archive image
    inspection_decision_destinationaudit_image_archive
  6. 06
    For fail: signal reject with defect class, archive image with classification
    inspection_decision_destinationaudit_image_archive
  7. 07
    For uncertain: route to human review station, hold item if line speed allows
    human_qc_review_station
  8. 08
    Capture human verdicts and feed back into model retraining loop
    model_retraining_loop
EMISSIONS · 3

Structured outputs this pattern produces. Other patterns and client systems can subscribe to them, which is how the catalog composes over time.

  • defect_rate_signal

    Per-defect-class and per-SKU defect rates over time. Single most valuable operational signal.

    CONSUMED BY
    • production quality dashboards
    • supplier performance reviews
    • manufacturing engineering
  • false_positive_signal

    Items the pattern flagged that humans overturned. Critical for tuning the false-positive rate against throughput cost.

    CONSUMED BY
    • pattern tuning workflows
    • operations review
  • drift_detection_signal

    Statistical shifts in input image characteristics (lighting changes, equipment degradation) that affect inspection.

    CONSUMED BY
    • maintenance alerting
    • calibration scheduling