The Challenge
On the factory floor, every stitch — and every pause — adds up.
A leading towel manufacturer had installed cameras above their stitching tables.
The goal was simple: maximize productivity.
But the footage sat unused, offering no insights into actual throughput or worker behavior.
They needed a way to track two things:
- How many towels were folded at each table
- When workers were active, idle, or on break
Manual monitoring was out of the question.
It was time to teach machines to watch, understand, and report.
A Day in the Life: Before Our Solution
Supervisors walked the floor every hour with clipboards in hand.
Some workstations moved faster than others, but no one had clear numbers. Counting folded towels relied on end-of-day samples. Breaks were estimated. And the entire reporting process was disconnected from their operations software.
On paper, throughput looked consistent.
In reality, productivity fluctuated — and no one could say why.
Pain Points:
- No automated way to count towel output from stitching tables
- Worker breaks went untracked or misestimated
- Real-time insights into productivity were unavailable
- Data couldn’t be fed into downstream systems like SAP
- Supervisors spent time manually observing instead of optimizing