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AI-Enabled Computer Vision for Zero-Defect Manufacturing: A Scalable Architecture for Industrial Resilience and National Competitiveness

This research introduces a modular, AI-enabled computer vision (AI-CV) architecture designed for zero-defect manufacturing (ZDM), aligned with Industry 4.0 goals. The system leverages hybrid CNN-Transformer models, federated learning, and human-in-the-loop (HITL) optimization to achieve 99.2% defect detection accuracy while minimizing latency and maximizing economic return. The architecture supports multi-plant scalability, compliance with ISO 9001 standards, and delivers a 22% ROI over five years. Applications span automotive, semiconductor, aerospace, and consumer electronics, with an emphasis on supply chain resilience and national competitiveness.

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