A Hybrid Vision-Language Architecture for Automated Defect Reasoning and Report Generation in Industrial Inspection

Industrial inspection requires more than binary anomaly detection: a practical system should determine whether an anomaly exists, localize the defective region, identify the defect type, and provide interpretable visual evidence. Existing CLIP-based methods detect and localize anomalies well but offer limited language-level defect understanding, while instruction-tuned vision-language models can describe defects but do not natively produce pixel-level masks. We introduce GenAU, a Generalist vision-language framework for industrial Anomaly Understanding that unifies image-level detection, pixel-level segmentation, multi-type anomaly detection, and defect analysis in a single instruction-following model. GenAU augments a vision-language model with two segmentation tokens, [SEG_defect] and [SEG_normal], whose hidden states act as language-grounded queries over multi-scale visual features for pixel-level localization; the image-level score fuses this map with the decoder's textual normal/defect decision, while the language decoder produces structured defect-aware responses. Trained with a joint language-modeling and segmentation objective, GenAU covers all four tasks within one architecture and recipe, adding zero-shot multi-type detection and language-grounded defect analysis at a quantified cost to detection and segmentation. Across cross-dataset benchmarks, GenAU attains the strongest image-level detection among CLIP-based zero-shot methods on VisA and Real-IAD, with segmentation approaching but not surpassing specialized CLIP baselines.

Bridge inspection in Japan requires mandatory visual assessments every five years, yet qualitative damage ratings (levels a-e) assigned by different engineers exhibit significant inter-rater variability -- a critical barrier to consistent infrastructure management. The aging of skilled engineers further threatens inspection capacity. This paper presents a methodology for automating bridge damage understanding and repair priority scoring using fine-tuned Vision-Language Models (VLMs). We fine-tune LLaVA-1.5-7B with QLoRA on up to 4,000 paired bridge damage images and inspection text records, then evaluate on a fixed test set of 800 images. The model outputs natural language descriptions identifying structural members and damage patterns, from which a rule-based scoring engine calculates a five-level repair priority index. A progressive training study (1k/2k/3k/4k samples) reveals that 2k training samples achieve near-optimal validation loss in only 2.9 hours of training; beyond 2k, validation loss improves by no more than 0.2% per doubling of training samples, exhibiting clear diminishing returns. Furthermore, semantic similarity on the held-out test set peaks at 3k (0.6909) and degrades at 4k (0.6739), indicating that quality-curated mid-scale data outperforms larger but noisier corpora. Inference optimization combining torch.compile() and batch processing (batch_size=8) achieves 10.06 seconds per image -- a 70.2% reduction over the unoptimized baseline. Our approach contributes to data governance in bridge inspection, reduces inter-rater variability, and provides AI-assisted triage to augment expert engineers in inspection workflows. Furthermore, we introduce a two-stage Quality Guard using a fine-tuned Swallow-8B SLM to reject low-quality VLM outputs before priority scoring, preventing spurious scores from damaged or unrecognised images.

Deploying AI-based visual inspection in manufacturing is hard because requirements change often, new defect types appear, and large labeled datasets are rarely available. We propose answer-conditioned chain-of-thought (CoT) distillation for rapidly adapting small vision-language models (VLMs) to new industrial tasks using minimal labeled data. A frontier VLM receives each training image along with its correct label and generates a justified visual explanation. A 3B-parameter model is then fine-tuned on these reasoning-augmented examples via LoRA. By conditioning on correct answers, we ensure all training reasoning is directed toward the correct conclusion, which is critical because frontier models score as low as 24.1% on our hardest task. We validate on four industrial classification tasks spanning three image modalities using only 18 to 30 labeled images per task. Across 4 seeds per task (32 training runs), our method outperforms direct fine-tuning on all 16 seed-task combinations, with mean improvements of +1.7 to +4.4 percentage points. A controlled equal-budget experiment confirms the improvement comes from reasoning quality, not additional training steps. An unconditioned baseline demonstrates that with out answer-conditioning, wrong reasoning degrades performance by 17.8 percentage points. On weld radiograph classification, the fine-tuned 3B model outperforms GPT-4.1 by 10.0pp using just 24 training images.