From manual counting to real-time production visibility

Client profile

Extra Colors is a modern paint company specializing in high-quality paints, wall coatings, façade systems. With a strong focus on innovation, quality, and continuous improvement, the company has built a broad portfolio of products serving professionals, builders, and homeowners.

The Problem: Manual Production Tracking

The factory produces dozens of bagged products, with hundreds of units moving through the line every day. Previously, production quantities were recorded manually, making it difficult to keep an accurate and up-to-date view of production and inventory.

With many different products being manufactured, even small counting errors could affect inventory records. A product might appear to be sufficiently stocked when the actual quantity is lower than expected, or additional production could be scheduled unnecessarily. These discrepancies can make production planning more difficult and may contribute to delays in fulfilling customer orders.

The challenge was to create a reliable way to track production quantities automatically while giving managers a clear view of what was happening on the production line.

The Solution: Real-Time AI Production Monitoring

We developed an AI-powered production monitoring system that automatically detects and counts products as they move along the conveyor belt.

An industrial camera was installed above the production line, and a computer vision model was trained to recognize the different products being produced. As each bag passes through the camera's field of view, the system identifies the product and updates the production count in real time.

The collected data is sent to a dedicated dashboard, where managers can monitor production activity and quantities in real time. The system also keeps a complete history of production, providing a reliable record that can be used alongside inventory information for planning and analysis.

See the system in action

Watch a real example of the AI-powered production monitoring system in use on a live production line.

The Results: Better Visibility, Better Production Planning

With automated production monitoring, the team gained a more reliable and transparent view of production activity. Instead of depending on manual counts and records, managers can now see how many units of each product have been produced and monitor the line in real time.

The system helps reduce counting errors and provides more accurate production and inventory information. This improved visibility supports better production planning, helping the team identify when additional production is needed and reduce unnecessary production caused by inaccurate records.

By turning production activity into real-time, actionable data, the solution gives the business a stronger foundation for inventory management, production strategy, and meeting delivery requirements.