Bag Counting Solution for
a Large Cement Plant
A prominent cement manufacturing plant faced challenges in accurately counting and accounting for bags of various categories being loaded onto trucks for transportation at their loading bays. Manual counting was prone to errors, resulting in accounting discrepancies and pilferage. To address this issue, the company sought a modern, automated solution to streamline the bag counting process and enhance overall accuracy in accounting.
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Location
India
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End User
Pipe Manufacturer
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Cameras Installed
100+
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Industry
Metallics
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Problem:
The manual bag counting process presented several challenges for the cement plant, including:
- Errors in Counting: Manual counting led to inaccuracies, causing financial losses and potential discrepancies in inventory.
- Identification of Bag Categories: Bags of different categories were identified by their color, and manual counting often resulted in misclassification, impacting accurate accounting.
- Pilferage Concerns: The manual process left room for pilferage, as errors and discrepancies went undetected.
Solution:
To overcome these challenges, our team implemented a computer vision-based bag counting solution, leveraging the LogicLens Platform (LLP). The solution included the following key components:
- Video Cameras: Installation of high-resolution cameras at each loading bay to capture footage of the bag-loading process.
- LogicLens Studio (LLS): Utilization of LLS for developing the bag counting solution, allowing the aggregation and processing of video feeds from cameras to identify and count bags of different colors.
- Machine Learning Models: Implementation of cutting-edge machine learning models for computer vision to accurately classify and count bags based on their colors.
- ERP Integration: Seamless integration with the existing ERP software to ensure that bag counting data is synchronized with the company’s legacy accounting system.
- Truck Challan Management Integration: Integration with the Truck Challan Management system to account for the exact number of bags being loaded onto each truck, enhancing transportation logistics. The challan was also verified at the gates using our License Plate Recognition System
Results:
Upon implementation, the bag counting solution delivered the following results:
- Accuracy in Counting: The automated system significantly improved the accuracy of bag counting, eliminating errors associated with manual counting.
- Category Identification: Bags of different categories were correctly identified based on color, preventing misclassifications and ensuring accurate accounting.
- Pilferage Prevention: The automated system reduced the risk of pilferage by providing a reliable and transparent counting process and verification of challan at the factory gate.
- Pilferage Prevention: The automated system reduced the risk of pilferage by providing a reliable and transparent counting process and verification of challan at the factory gate.
Business Outcome:
The integration of the bag counting system brought about a transformative impact on the cement manufacturing plant:
- Error Reduction and Financial Gains: The system eliminated errors in counting, resulting in a significant reduction in accounting losses and increased profit margins.
- Streamlined Operations: The automated and accurate bag counting process streamlined operations at the loading bays, contributing to overall efficiency.
- Logistics Optimization: Integration with the Truck Challan Management system optimized transportation logistics by accounting for the exact number of bags loaded and transported by each truck. Successful implementation of the computer vision-based bag counting solution enhanced accuracy, reduced errors, and streamlined operations for the logistics department of the cement plant, showcasing the tangible business value delivered by our technology.