Optimization of the packaging process
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Optimization of the packaging process

16. December 2023 Print this page 3 Minutes reading time (515 words)
Manufacturing Tutorial

 

Optimization of the packaging process

 

Our client is a part of the international corporation. Since 2006, it has been designing and manufacturing coils, sensors, and switches for the automotive industry. The products it produces are used in passenger cars, trucks, construction machinery, agricultural machinery, and heavy equipment.

 

 

THE PROBLEM

 

Our client manufactures a wide range of coil types, which are packed into just a few types of packages. Each coil must go into the correctly labeled package, especially during the preparation of shipments. Otherwise, despite the lack of downtime in production, the consequences are twofold: first, a negative impact on the company's image due to incorrect product packaging, and second, additional costs associated with correcting the error by re-shipping the product.

 

These costs can be disproportionate to the product's value, especially when the error occurs in a remote part of the world.

 

 

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THE SOLUTION
 
After a deep analysis of the problem, OneStepAI team proposed the manufacturer implement a visual supervision system at the packer's workstation.
 
What did the proposal include?

The use of cameras at the stations along with an intelligent type recognition system.

Pairing of a given coil type with the appropriate package.

 
In case of an incorrectly matched coil to the package, the packing table top was to light up in red to inform.
 
The implementation period was divided into two stages:
Collecting data from the packing stations for the first three months - for this purpose cameras were used, and their installation was modified many times to provide the most accurate data and meet security requirements (e.g., GDPR).
Proof of Concept - that is proof created in the fourth month that the solution is feasible in practice.
 
     
 
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THE RESULTS
 
An interdisciplinary project team was established to create a solution to the customer's problem, consisting of employees of the coil manufacturing company and specialists from Intratel.
 
Thanks to the combination of technical and business knowledge, the team, using theOneStepAI.com platform, was able to develop an AI model that effectively recognizes different types of coils.
 
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Thanks to the use of the OneStepAI.com platform, the team could work on the project in close cooperation with the client, making ongoing corrections both in the training set and in the AI model. As a result, after just four months, the team was able to create an AI model and implement it at the packing station.
 
The proposed solution significantly reduced the number of incorrectly packed coils. In addition, the manufacturer noted decreases in shipping costs, which translates into increased company profitability. Our case study shows how the strategic use of OneStepAI can bring tangible benefits to enterprises.
 

About the Author

Marta Zarzecka
Marta Zarzecka
Rogówka