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Why Most 'AI Automations' Fail in Real Workflows

PMTheTechGuy
··2 min read
Why Most 'AI Automations' Fail in Real Workflows cover image

Every AI vendor promises the same thing: "Automate everything with AI!"

But in reality, most AI automation projects fail within 6 months of deployment.

Not because the AI is bad. But because the workflow design is bad.

Lesson learned: This is why my Document AI workflow emphasizes transparency over magic.


1. Overpromising AI Capabilities

The Demo: "Our AI reads invoices with 99% accuracy!"

The Reality: That's on their test data. On your messy, real-world invoices? Maybe 75%.

The Fix: Test the AI on your data before committing. Build in a confidence threshold: if the AI is less than 90% confident, flag it for human review.

2. Underestimating Data Cleanup

AI doesn't magically "understand" your documents. It needs:

  • Consistent file formats (all PDFs, not a mix of JPEG scans and Word docs).
  • Readable quality (300 DPI minimum for scans).
  • Structured layouts (forms work better than freeform text).

Most failures happen in the data prep stage, not the AI stage.

I spend 30% of my time on data validation before it even hits the AI.

3. Missing Validation Logic

The Trap: "The AI extracted the data, so it must be correct!"

The Reality: AI makes mistakes. Silently.

The Fix: Add validation rules:

if extracted_total < 0:
    flag_for_review("Negative total is impossible")
    
if extracted_date > today:
    flag_for_review("Future date detected")

Simple logic catches 80% of AI errors.

4. No Audit Trail

When something goes wrong, can you trace it back?

What you need:

  • Input file (stored).
  • AI output (logged).
  • Confidence score (tracked).
  • Timestamp (recorded).

Without this, debugging is impossible.

I log every Document AI call with:

  • Filename
  • Extracted fields
  • Confidence scores
  • Cost

This creates accountability. If a client says "the invoice was wrong," I can show them exactly what the AI extracted and at what confidence level.

Conclusion

AI is powerful, but it's not magic.

To make AI automation work:

  1. Test on your data (not demo data).
  2. Build validation rules.
  3. Add human-in-the-loop checkpoints.
  4. Log everything.

AI should augment human work, not replace it blindly.

Tags

#AI#Automation#Machine Learning#Production
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