Heavy industry · manufacturing & logistics · multi-site · 2024
Real-time vision system on the conveyors, dispatch belts, and loading gates, where every unit crossing the line is a unit of revenue. Camera feeds come in at 4, 8, or 12 streams per site at once and are analyzed on-device by a computer-vision model, no frame ever leaving the building. The work is split into three deliberate stages: spotting each unit, tracking it as one identity from frame to frame, and counting it once as it crosses the line. That separation is what lets the system hold up through occlusion, motion blur, and dropped frames without double-counting or losing a unit in between.
The camera count is cross-validated by two independent sensor channels at the same line: a motion sensor that confirms physical pass-through, and a heat sensor that confirms the unit's thermal signature against the expected envelope. Any disagreement between vision, motion, and heat is flagged as a contested count rather than silently reconciled. The system never picks a winner without surfacing the conflict.
Every counted unit is written the instant it is produced to a tamper-evident log, locked at the moment of the count, so the operator's count, the dispatcher's count, and the counterparty's count all reconcile against one record no one could edit after the fact. Before a site goes live, it is load-tested stream by stream until the hardware reaches its real limit, so each one is sized to what it can actually handle, not a guess.
