This case note covers the Line A pilot at a mid-size apparel and packaging facility near Istanbul. Customer name withheld for confidentiality.
Line A is a packaging line with ~4,200 pieces/day capacity. Scrap was mostly due to label alignment, stitch appearance, and packaging integrity.
Baseline metrics
Pre-pilot 30-day average scrap rate was 4.8%. Quality sampled at line end; in-line defects piled into rework queue.
Four existing IP cameras (pack in, mid, out, label station) connected via RTSP to edge box. No new cameras purchased.
What changed on Line A
Quality module classified each piece in 0.2–0.4 s. On deviation, quality engineer got panel alert and VMS popup.
After 30 days Line A scrap fell to 3.3% — 31% relative improvement. Rework queue volume dropped 45%.
Main gain was early separation, not end-of-line scrap cost alone.
Shift-level visibility
Hourly scrap curve shown to shift lead. Post-lunch spike traced to label roll — root cause closed within 48 hours.
Outcome and rollout
Pilot deployed in 5 business days, measured 30 days, written report delivered. Line B expansion planned on same edge stack.
* Customer name and facility details are not shared for confidentiality. Results may vary by facility conditions.