The Challenge
The client (a high-volume textile manufacturer) had invested in camera systems across their factory floor. But those feeds sat underutilized.
They couldn’t see how many towels were being folded per station. Nor were breaks monitored. Supervisor walkthroughs were infrequent and subjective.
Management wanted real metrics:
- How many units per hour?
- Who’s idle, and when?
- Which stations consistently underperform?
Manual tracking was impossible at scale. They needed eyes that didn’t blink, and brains behind the lens.
A Day in the Life: Before Our Solution
Every shift ended with a number — total towels folded.
But how did that number come to be? Somehow, no one really knew.
If one station underperformed, managers were left guessing:
- Maybe the folder took an unscheduled break
- Maybe the towels were bulkier
- Maybe the camera just didn’t catch the right angle
Supervisors walked the floor when they could, but it was impossible to track every table, every hour.
The video feeds were there; but reviewing them was tedious, expensive, and too slow to act on.
There was no way to measure individual throughput. No way to catch inefficiencies in real time. And, no way to know who was working, who was waiting, or why production dipped.
Decisions were based purely on gut feel. And performance blind spots only grew with scale.
Pain Points:
- No automated way to count throughput per table
- No system to detect idle time or break duration
- Limited visibility into operator activity and role segmentation
- Underused video infrastructure
- Manual tracking too slow and inconsistent