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intuBlog - intuVision Manufacturing - Loss Prevention

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Bread Factory Loss Prevention intuVision/ IntellModus

Anna Vacha, Emil Filipovski

"By counting and comparing the numbers of dough balls, baked and packaged bread from conveyor belt cameras in real-time, the factory can pinpoint the problems during each production run. Due to the asynchronous nature of the bread making process and the high speed of product moving on the conveyor belts, other counting solutions did not work well. We choose intuVision video analytics system to accurately count each phase of the production line and associate production cycles in reporting. Our camera system with intuVision Video Analytics detects where the production losses are and prevents them."
Emil Filipovski, Managing Director, IntellModus

The Customer Challenge

One of IntellModus’ customers, a large bread factory needed an automated and reliable loss-prevention solution to count the dough balls, baked loaves and packaged bread along each production line to increase the efficiency of their operations.

The Solution - intuVision VA Traffic

IntellModus came to intuVision for streamlining real-time product counts from conveyor belt cameras to generate reports for each production cycle. intuVision customized a counting solution to fit the factory requirements. The reports show the sources of loss for each production cycle in a timely fashion so that needed actions can be taken to improve efficiency.

Benefits
  • Video based reliable loss-prevention
  • Improved factory operation efficiency
  • Precise monitoring of the process
  • Custom reports for production cycles

Equipment-at-a-Glance

Hardware: 90 Dahua IP cameras and NVR, COTS servers for video analytics.

Software: intuVision VA Power v6.0, Custom Reports

Solution Details

IntellModus analyzed the factory operations and established the solution requirements. Throughout the brad factory they installed over 90 cameras, three cameras per production line to monitor the conveyor belts for the dough balls, baked loaves and packaged bread. IntellModus worked with intuVision to determine the optimal positions for the cameras over the conveyor belts to reach accurate counts using video analytics.

The system feeds live video from the cameras into intuVision Video Analytics to be analyzed in real-time to:

  • Detect dough balls starting on the conveyor belt and count them
  • Count the baked loaves and the packaged bread on the second and the third conveyor belts of that production line
  • Associate the baked and packaged loves with the corresponding dough production taking into account the rising times and generate report for the production cycle

The production cycle item counts and losses at each step are detailed for every run, the reports are automatically e-mailed to responsible operations personnel for each shift. Being able to see these reports immediately helps operations managers to address the production problems and losses in a timely manner.

Results

Using intuVision video analytics IntellModus delivered an automated loss-prevention solution for the bread factory. intuVision VA provides accurate counts of product at each stage of manufacturing process and provides custom reports summarizing production cycle’s throughput.

Monitoring and automatically detecting sources of loss during production significantly increased the operational efficiency of the factory.

You can contact us at info@intuvisiontech.com or call to learn more about how intuVision VA and find out how it could fit into your work flow needs.

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