Machine Vision & Industrial Inspection AI worked example

Inspection Labor Savings at 23% fatigue, break, and handling allowance: a worked example

This scenario runs the inspection labor savings calculation on the strong side: 23% fatigue, break, and handling allowance, with every other input held at its documented default. Use it when building the labor savings portion of an inspection automation business case and you need to document how many inspector hours are displaced per shift.

The inputs for this scenario

  • Parts removed from manual inspection per shift: 3,600 parts / shift (unchanged)
  • Manual inspection rate: 8 parts / min (unchanged)
  • Fatigue, break, and handling allowance: 23 % (raised for this scenario; the documented default is 20)

Working through the calculation

  • Applying the documented formula (Base manual inspection time = parts per shift / manual inspection rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 554 hr for inspector hours displaced per shift, the number this scenario is built around.
  • At this operating point the engine returns 450 hr for base manual inspection hours.
  • At this operating point the engine returns 23 % for fatigue and break allowance.
  • At this operating point the engine returns 8 pieces / min for manual inspection rate.

How this compares with the baseline

  • Against the tool's baseline example, where fatigue, break, and handling allowance sits at 20% and the headline result is 540 hr, this scenario comes in 2.5% above the baseline at 554 hr.
  • Use it when building the ROI for a vision investment, planning to redeploy inspectors, or quantifying the labor content of a manual inspection task. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Inspector hours displaced per shift: 554 hr (headline result)
  • Base manual inspection hours: 450 hr
  • Fatigue and break allowance: 23 %
  • Manual inspection rate: 8 pieces / min

Run it with your numbers

  • Every input above is editable in the live Inspection Labor Savings calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.