Machine Vision & Industrial Inspection AI worked example

AI Inspection Sample Size at 63% vision system availability during validation: a worked example

Suppose vision system availability during validation falls to 63%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate the total number of parts needed to conduct a statistically meaningful AI inspection model validation, based on required validation runs, parts per run, system availability, and the expected proportion of non-defective parts in the sample.

The inputs for this scenario

  • Number of validation runs planned: 4 runs (held at the documented default)
  • Parts inspected per validation run: 250 parts / run (held at the documented default)
  • Vision system availability during validation: 63 % (the input this scenario stresses; the baseline uses 88)
  • Proportion of conforming parts in the sample: 80 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total planned parts = validation runs x parts per run.
  • Conforming parts in validation sample works out to 504 parts at these inputs, and this is the headline figure for the scenario.
  • Total planned validation parts works out to 1,000 parts at these inputs.
  • Parts lost to system unavailability works out to 370 parts at these inputs.
  • Defective parts in sample works out to 126 parts at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where vision system availability during validation sits at 88% and the headline result is 704 parts, this scenario comes in 28.41% below the baseline at 504 parts.
  • It computes total planned parts, the realistic sample after availability losses, and the conforming and defective parts within that sample. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Conforming parts in validation sample: 504 parts (headline result)
  • Total planned validation parts: 1,000 parts
  • Parts lost to system unavailability: 370 parts
  • Defective parts in sample: 126 parts

Run it with your numbers

  • To rerun this with your own numbers, open the live AI Inspection Sample Size calculator, set vision system availability during validation to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.