How to handle too many AOI false alarms in an electronics factory? Production line debugging experience

When there are too many AOI false alarms, you cannot simply let the operator keep clicking 'pass,' nor can you just loosen the thresholds and call it solved. When there are many false alarms, the line slows down, IPQC gets annoyed, and eventually, real defects are easily overlooked. I encountered a line where the silkscreen next to a resistor was constantly being flagged as an offset due to…