Research · Production-line computer vision
Industrial Object Counting
Exact counts of items moving at speed on a production line, where counting by hand is close to impossible. First deployed for steel bars at dispatch.
- Client
- Steel manufacturer
- Type
- Production-line computer vision
- Industry
- Manufacturing
The challenge
On a fast line, people cannot count reliably, and standard detect-and-track counters merge items that touch. At steel dispatch, they undercounted bars that touched at panel seams.
What we did
- 01Replaced tracking with a threshold-crossing signal at the checkpoint line, the same principle as a road loop detector.
- 02Kept a fine-tuned YOLO11 detector purely for visual QA overlays.
- 03Built a second pipeline for handheld footage, counting only items that cross upward so vibration does not double-count.
What we delivered
- Real-time counter for RTSP cameras
- Annotated output video and event log
- Calibration tool for new camera setups
Where it runs
One technology, proven on a real site.
The same method counts
- Steel bars and pipes
- Cartons and boxes
- Bottles and cans
- Fasteners and parts
- Sheets and panels
- 01Steel · Steel manufacturer
Rebar counting at dispatch
Bars were counted by hand before dispatch: slow, and wrong often enough to cause disputes with customers.
- One camera over the checkpoint, starting with no labelled training data
- A threshold-crossing signal that counts each bar once, even when bars touch
- An annotated video and event log for every dispatch
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