All case studies  /  Part traceability
Automotive manufacturingA Tier-1 automotive parts plant · two sites

Every part tracked from station to station, so nothing goes missing unnoticed.

A Tier-1 auto parts maker with two plants. Its systems knew what each machine did, but not where each part was.

Illustrative video, generated for this page. A camera over a gate counts each tray. Not the plant.
In numbers
48
parts per tray, counted at every gate
Counted from above in a second or two.
Seen on site
2
plants
Today parts are only counted at packing.
Seen on site
14
working days to a running trial
On one conveyor first.
Planned
ROI

Where it saves money.

An estimate for one plant, based on what we saw on the floor. The trial turns it into measured numbers.

$30K to $60K
saved a year, one plant
Fewer lost parts, fewer line stops, less counting by hand.
Estimate
$9K to $29K
a year of lost parts saved
From 30 to 60 parts lost a month, at $25 to $40 each.
Estimate
$11K to $18K
a year of line stops avoided
From 6 to 10 hours a month of disputes over counts, at $150 an hour.
Estimate
What they had before

They knew the machine. Not the part.

Parts move 48 to a tray, with their codes hidden once stacked. They were only counted at packing. When a part went missing, nobody knew where.

What we set up

A digital twin first. Then count every tray.

01
Digital twin first

We rebuilt the gates and conveyors in 3D from the plant drawings and chose camera spots before mounting anything.

02
Count

A camera over each gate counts the tray. 48 in, 48 out.

03
Read

The plant's own reader scans each part code once.

04
Link

Each part code is linked to its tray, so the tray carries the list down the line.

05
Record

Each station's part list goes into the plant's system. A short count goes to the supervisor.

How the check works
48 IN · 46 COUNTED · SUPERVISOR TOLD GATE 3 · WASHING → ASSEMBLY
A tray of 48 counted from above. If parts are missing, the supervisor is told at that gate.
What they hold now

Every part has a history.

From the day a part is made to the day it ships, its path is in the plant's own system. A missing part points to the station where it went missing.

The camera is the input. The record is the product.

On site

How it runs on site.

Where it runsOn a small Zapdos box on the plant network.
VideoOnly a few frames as each tray passes. No video is kept.
What leavesNothing. The part list goes into the plant's own system.
If the plant system is downCounting carries on. The lists are sent once it is back.

See your own site in this view.

Tell us the check in one sentence. We set it up on the cameras you already have. You judge it on the record.