Three engagements, anonymized, in full technical detail.
Client names withheld under standard confidentiality; every number below is from the delivered technical specification.
Challenge
Static standard-time line balancing sized every shift for a single worst-case or averaged model, causing chronic over-manning on light days and line breaches when heavy-work-content models dominated the daily mix.
Approach
A proportional weighted-average aggregation engine blends per-model micro-task work content by the true daily plan mix, ingests plan data directly from the production-planning system, and persists shuffling constraints and audit history to a relational database layer.
Result
Industrial engineers now simulate line-balancing efficiency and required manpower before a shift runs, with every manual and automatic rebalance logged for audit — replacing spreadsheet-based guesswork with a live predictive planner.
Challenge
Human visual inspection varied operator to operator; ambiguous defects stalled the line waiting on specialist review, and microscopic defects occasionally escaped to the next production stage entirely.
Approach
A five-stage edge pipeline — pre-inference image-quality gating, golden-baseline structural-similarity matching, deep-learning defect segmentation, and spec-referenced pass/fail logic — with every stage logged to a relational audit table.
Result
Line operators get an automated, mathematically-measured PASS/FAIL decision in under 30 seconds, matching senior specialist rulings on a held-out validation set and freeing specialists to focus on genuine edge cases.
Challenge
Fourteen independent data sources fed a scoring formula whose weights didn't reconcile, and a lead with sparse data looked identical to one confirmed cold — actively misleading prioritization.
Approach
A slot-based design maps every source onto one of eight fixed-weight slots and takes the strongest signal within a slot rather than summing — preventing double-counting — alongside a parallel data-confidence budget so unqueried data is never read as a negative result.
Result
A single ranked worklist with a deal-readiness grade, projected value and urgency deadline per lead — plus portfolio heatmaps and a daily "newly hot" digest — turning a raw score into an answer to "who do I call this week."