Production line monitoring with computer vision

The problem

How it works

1. 1Cameras covering stations, conveyors or machine outputs are connected over RTSP/ONVIF.
2. 2Models detect product flow, machine activity and operator presence per station.
3. 3Events are converted into running/stopped intervals, cycle times and counts.
4. 4Shift dashboards show availability, performance indicators and downtime by station.

What can be detected

• Line or station stop, including micro-stops
• Cycle time per unit or batch
• Output count per station and shift
• Station unattended while the line is running

Typical scenarios

• Assembly and packing lines
• Older machines without PLC connectivity
• Bottleneck analysis across stations
• Shift handover reporting

Working with existing cameras

• The product flow or machine output must be visible in frame.
• Higher frame rates are needed for fast lines; this is checked during camera assessment.
• Most IP cameras and NVRs that provide RTSP or ONVIF streams can be connected, regardless of brand.
• Before a pilot, sample footage from each candidate camera is reviewed for resolution, angle, distance and lighting.
• Where a view is not suitable, the recommendation is usually to reposition the camera or add one — not to replace the whole system.

Integration

• REST API / webhook to MES or ERP
• Export of shift reports
• Dashboard for supervisors and management

Privacy and security

• No face recognition is used in safety and operations analytics; events describe what happened, not who.
• On-premise processing keeps video inside your network.
• Evidence clips, retention periods and user access are configurable and should follow your GDPR/KVKK policies.
• Workplace monitoring should be introduced with clear employee information and, where applicable, consultation with employee representatives.

Limitations

• Camera-derived metrics are as good as the view of the process; hidden steps need additional cameras or data sources.
• Reason codes for stops may still need operator input or integration with existing systems.