Pipe Counting Solution for
Leading DI Pipe Manufacturer in India
A leading Ductile Iron (DI) pipe manufacturer in India has been facing challenges in their production process due to manual pipe counting. Counting pipes manually led to accounting losses and possible pilferage, as errors and inaccuracies were inevitable. To address this issue, the company sought a modern, efficient solution to automate the pipe counting process and enhance overall production accuracy.
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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 pipe counting process posed several challenges for the DI pipe manufacturer, including:
- Errors in Counting: Manual counting resulted in inaccuracies, leading to financial losses and potential inventory discrepancies.
- Time-Consuming Process: Counting pipes across multiple production lines manually was time-consuming, affecting overall operational efficiency.
- Lack of Real-time Data: The absence of real-time data hindered the company’s ability to make informed decisions promptly.
Solution:
To overcome these challenges, our team implemented a computer vision-based solution powered by our LogicLens Platform (LLP). The solution involved the following key components:
- Video Cameras: Installation of commodity video cameras at strategic positions across production lines to capture footage of the pipe manufacturing process.
- LogicLens Studio (LLS): Utilization of LLS, our low-code, business solution development studio, for developing the pipe counting solution. The solution enables the aggregation and processing of video feeds from the cameras to identify the count of good and scrapped pipes of different dimensions with the help of cutting-edge machine learning models for computer vision.
- Integration with ERP: Seamless integration with the existing ERP system to ensure that pipe counting data is synchronized with the company’s broader operational framework.
- Notification Channels: Implementation of various notification channels, like SMS, Emails, Telegram to disseminate real-time, analytical information to relevant stakeholders after each shift.
Results:
Upon implementation, the pipe counting solution delivered the following results:
- Increased Speed: The automated system significantly accelerated the counting process compared to manual methods, contributing to enhanced operational efficiency.
- Objective Counting: The computer vision-powered system ensured an objective and accurate counting process, eliminating errors associated with manual counting.
- Real-time Data: Stakeholders gained access to real-time data, enabling prompt decision-making and improved overall responsiveness to production challenges.
Business Outcome:
The integration of the pipe counting system has brought about a transformative impact on the DI pipe manufacturing company:
- Error Reduction: The system eliminated errors inherent in manual counting, resulting in a significant reduction in accounting losses and increased profit margins.
- Improved Operational Efficiency: With an automated and objective counting process, the company experienced heightened operational efficiency across all production lines.
- Enhanced Profitability: The elimination of pilferage and accurate accounting led to a gross increase in the profit margin, showcasing the tangible business value delivered by the computer vision-based solution.