AI Vision Counting Machine for Hardware Fastener Packaging ## Project Background

Project Background

A leading hardware fastener manufacturer producing screws, nuts and spring washers was facing major bottlenecks in its packaging workshop. Traditional manual counting required 4‑6 workers for sorting and counting small‑size hardware parts. Long‑hour manual work caused frequent miscounts, missing counts and duplicate counts. Wrong‑quantity shipments triggered customer complaints and high re‑packing costs. Fiber‑optic counting machines previously used failed to handle overlapping and stacked parts, resulting in unstable counting accuracy.

The client was looking for an automatic counting solution to cut labor cost, improve counting consistency and realize traceable production data for quality control.

Solution

After sample testing and technical communication, our AI vision counting & packaging machine was selected for full‑line deployment.

• Adopts high‑speed industrial CCD camera and self‑developed AI vision algorithm, accurately identifies stacked, overlapping and reflective small hardware parts.
• Counting accuracy: ≥99.9%, counting speed up to 120‑180 parts per second.
• Integrated automatic feeding, counting, bag‑filling, sound‑light alarm and NG rejection function.
• Supports open API to connect with customer’s existing MES system for real‑time output data recording.
• Multi‑language HMI for easy operator setup, no professional algorithm skills required.

On‑site Operation Result

1. Labor Reduction: One single machine replaces 4 manual counting positions. The customer cut labor expenditure in packaging workshop significantly.
2. Accuracy Improvement: Counting error rate dropped from over 3% (manual work) down to below 0.1%. Wrong‑quantity delivery complaints were almost eliminated.
3. 24‑h Stable Production: The machine runs non‑stop for day‑shift and night‑shift, matching the customer’s high‑volume production rhythm.
4. Data Traceability: Production batch, output quantity and operation logs are automatically saved. All counting records can be exported for quality review.