Candy Counting Project
Food & BeverageLeading manufacturer of candy, chocolate, and confections seeking to optimize production efficiency
Challenge
- Unable to track individual piece count for candy production on monthly/daily/shift basis
- Lack of meaningful efficiency measurements led to overproduction
- Significant product waste due to production estimation issues
Solution Delivered
Hardware Components
- Two pilot control panels
- Rockwell/CompactLogix PLC integration
- Ignition Edge gateway implementation
- Operator pendant installation
- Keyence line scanner (camera) system
Implementation Services
- PLC programming
- Ignition configuration
- Line scanner integration
- System testing and validation
Key Functionalities
- Automated recognition of various chocolate shapes via line scanner
- Real-time counting of products on fast-moving conveyor
- Batch tracking and management in PLC
- Dual counting methods to accommodate different packaging requirements
- SAP ERP system integration for batch and sub-batch reporting
Results
Immediate Outcomes
- Validated accurate automatic chocolate counting capability
- Successfully demonstrated concept effectiveness
- Achieved reliable production metrics
Expansion Status
- Currently testing additional production lines
- Validating system with various chocolate shapes
- Planned deployment across all 20 production lines upon validation
Business Impact
- Enhanced production tracking accuracy
- Improved inventory management
- Reduced waste from overproduction
- Enabled data-driven efficiency measurements
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