Production line efficiency monitoring with one existing camera: machine uptime, workstations and safetyWith a single overhead camera, AI monitors machine run/idle time, staff workstations and hazardous zones on a production line 24/7 — making line efficiency measurable.2024-12-10
On a textile production line, line efficiency long relied on the supervisor's eye and manual records: how long the machine actually ran, what each operator was doing and the risk along the crane travel path were not measured. Hype Vision connected a single existing overhead IP camera over RTSP and built a platform that detects machine status, staff workstations, material flow and safety zones from the same image — all fully on-premise.
The problem: why line efficiency could not be measured
Line efficiency depended on shift-time observation and forms filled in afterwards. How long the machine really ran and how long it stopped was unknown, and downtime reasons were not logged.
The same area had staff in different roles (operator, quality check, assembly) and heavy crane traffic. Who was at which station, how busy stations were and the safety risk along the crane path could not be monitored continuously.
Machine run and idle time (basis for OEE)
The production machine was defined as a zone in the camera view; the model continuously detects whether it is running or stopped. Run and idle times are logged with timestamps, so planned and unplanned stops can be separated and line efficiency tracked with OEE logic.
- Instant running / stopped detection
- Timestamped logging of run and idle time
- Machine utilisation by shift and day
- Review of stoppages with video evidence
Staff and workstation analytics
Staff on the floor are detected anonymously and labelled by role based on their zone (operator, quality check, assembly). Station occupancy and active vs idle time are separated, making the line's real workflow visible.
Faces are not recognised; tracking uses anonymous IDs, so the analysis is designed to be privacy-compliant.
- Zone/station-based staff detection
- Station occupancy and active/idle split
- Role-based workflow visibility (operator, quality, assembly)
- Anonymous tracking — no facial recognition
Material and zone tracking
Raw-material rolls, fabric sheets to be processed and the work area are defined as separate zones. Whether material is in the correct zone and movement in the work area are made visible, so line efficiency can be assessed together with material flow.
- Zones for raw material and work material
- Alert for material left in the wrong zone
- Work-area occupancy and movement
Safety: the crane travel path (hazardous area)
The crane travel path was marked as a hazardous area. When staff enter it or a pedestrian conflicts with the crane path, an instant alert is raised and the event is logged with an evidence frame — so safety is checked from the very same camera used for efficiency.
- Instant alert on hazardous-area (crane path) violation
- Event logging with evidence frames
- Efficiency and safety from one camera
On-premise architecture and privacy
All analysis runs on a server inside the plant; video never leaves the site. One camera feeds the machine, staff, material and safety modules at once. People are not identified, tracking uses anonymous IDs and faces are blurred.
Outcome
Line efficiency moved from shift observation and forms to continuous, measurable monitoring. Machine stops, station occupancy and safety violations are tracked on one screen with timestamped data.
- Machine run/idle time measured continuously
- Station and staff workflow made visible
- Hazardous-area violations logged
- Production and safety teams work from the same data
Related solutions
Frequently asked questions
Do I need a new camera for line efficiency?
In most cases no. An existing overhead camera with RTSP/ONVIF is enough; machine status, staff and safety are all analysed from the same feed.
Is this an OEE measurement?
By measuring machine run and idle time it feeds the availability component of OEE directly. Additional modules can be added per line and product for the quality and performance components.
Is measuring staff activity a privacy problem?
The analysis is anonymous; faces are not recognised and tracking uses anonymous IDs. Technical measures (on-premise processing, retention periods, role-based access) and data-controller duties are still defined together with the plant.
Does video leave the plant?
No. The deployment is on-premise; analysis runs on a server inside the plant and only event and metric data reach the dashboard.
