Uttam Strips: machine-wise production counting, downtime and manpower monitoring on an AIDA 5 press
Uttam Strips' management wanted machine-wise visibility on their AIDA 5 stamping press: who was deployed, what was produced and why it stopped. VIZO361° answered all three from three existing cameras — automated rotor / stator counting, 60-second inactivity detection per belt, required-vs-observed manpower and attendance by face.
At a glance
One press, three cameras, four outputs
- Customer
- Uttam Strips
- Site type
- Stamping division — rotor and stator production
- Machine
- AIDA 5 press (3 conveyor belts: Belt 1 rotor, Belt 2 stator, Belt 3 stator)
- Cameras
- 3 — conveyor camera, workforce camera, wide camera view
- Scope
- POC scope supplied by Uttam: production counting, machine downtime, manpower monitoring, attendance by face
- POC period
- October 2026 (shift evidence from 6–7 October; period view 1–8 October)
The challenge
Management wanted machine-wise visibility
Uttam Strips runs rotor and stator stamping on an AIDA 5 press. Management had an approved machine roster, a required staffing level and a production plan, but no independent record that connected the three at the machine. The questions put to the POC were simple to ask and hard to answer from the shop floor: who was actually deployed at AIDA 5 during each shift, what did the press actually produce hour by hour, and why did it stop when it stopped?
What was planned?
Required staffing, assigned operator and the approved machine roster.
What was observed?
Production counting, camera-area availability and production inactivity.
What needs action?
Staffing gaps, operator cover, stop reasons and resource allocation.
The management purpose, in the customer's own framing: connect deployment, production and downtime to machine-wise performance and cost review — using the observations together with approved payroll and allocation records.
What VIZO361° does on AIDA 5
Four outputs from three existing camera views
Conveyor camera
- • Automated production counting
- • Production inactivity
- • Direct-pickup evidence
Workforce camera
- • Required 4 staff + 1 operator
- • Area presence and shortages
- • People attendance evidence
Wide camera view
- • Wider machine context
- • Live supervision
- • Visual review of the machine area
Three camera views support one AIDA 5 setup. Camera count and conveyor-belt count are different: the press has three belts (Belt 1 rotor, Belt 2 and Belt 3 stator) covered by one conveyor camera.
Scope 01
Production counting
Automated rotor / stator output by hour and by shift for production review.
Each part crossing the conveyor is counted from the camera. The shift report shows date, shift window, hourly rotor count, hourly stator count and total quantity; the dashboard adds hourly and belt-wise trends and a selected-period view.
Scope 02
Machine downtime
Inactive periods identified per belt so the line team can explain each stop.
DOWN means no recorded part crossing for 60 seconds — the report measures production inactivity, not a fault code. Every interval has a clear start and end time (IST). Belt intervals overlap, so they are reviewed belt-wise and must not be added into a single machine-breakdown total.
Scope 03
Manpower monitoring
Required deployment (4 staff + 1 operator) compared with observed availability.
The workforce camera reports how long at least 4 staff were visible, how long fewer than 4 were visible, and how long the designated operator area had no person in it. Operator availability is reported separately so it does not inflate the four-person staff count. Staff-shortage and operator-presence alerts fire during the shift.
Scope 04
Attendance by face
Named presence, assigned shift and first / last seen for roster review.
A named attendance card with the assigned shift, the time of the first and latest camera observation, and the camera frame to cross-check the entry. Observation times do not establish continuous time working at the machine.
Shift evidence
What two shifts on AIDA 5 recorded
Day shift: 6 Oct 2026, 07:00–19:00 IST. Night shift: 6 Oct 2026, 19:00 – 7 Oct 2026, 07:00 IST. All figures are as recorded by the system and saved in the day / night production, downtime and manpower reports.
| Observation | Day shift | Night shift |
|---|---|---|
| Production | ||
| Rotor counted | 9,891 | 8,005 |
| Stator counted | 9,589 | 7,892 |
| Total parts | 19,480 | 15,897 |
| Downtime (per belt, overlapping) | ||
| Belt 1 · Rotor — DOWN | 2h 36m 52s | 4h 07m 20s |
| Belt 2 · Stator — DOWN | 2h 42m 39s | 4h 17m 13s |
| Belt 3 · Stator — DOWN | 2h 42m 35s | 4h 16m 33s |
| Manpower (required 4 staff + 1 operator) | ||
| At least 4 staff visible | 1h 59m 14s | 29m 54s |
| Fewer than 4 staff visible | 9h 58m 55s | 11h 29m 15s |
| Exactly 2 staff visible | 3h 15m 59s | 5h 18m 54s |
| No person in operator area | 7h 18m 40s | 8h 00m 31s |
- • DOWN = no recorded part crossing for 60 seconds. Belt intervals overlap and must not be added into a single machine-breakdown total.
- • Camera-area gaps identify periods to review; they do not by themselves prove paid absence or its cause.
- • Management action recorded against this evidence: verify deployment, arrange operator cover and investigate the stop windows.
Every stop has a start and an end time
| Shift | AIDA 5 | Start (IST) | End (IST) | Duration |
|---|---|---|---|---|
| Day | Belt 1 | 7:00:00 AM | 7:22:10 AM | 0h 22m 10s |
| Day | Belt 2 | 7:00:00 AM | 7:21:58 AM | 0h 21m 58s |
| Day | Belt 3 | 7:00:00 AM | 7:22:05 AM | 0h 22m 05s |
| Night | Belt 1 | 10:03:14 PM | 11:26:17 PM | 1h 23m 03s |
| Night | Belt 2 | 10:03:14 PM | 11:28:40 PM | 1h 25m 26s |
| Night | Belt 3 | 10:03:14 PM | 11:28:49 PM | 1h 25m 35s |
Example intervals from 6 October 2026, shown to whole seconds; shift totals use the precise recorded durations.
The operating loop
Observe → supervisor review → recorded action
Automation supplies the observations; the operating team records the reason and the response. The loop closes every shift.
| Automated observation | Supervisor review | Action to record |
|---|---|---|
| Below required staff / empty operator area | Check roster, breaks, redeployment and camera evidence | Restore cover or document the approved reason |
| Extended machine / belt inactivity | Ask the operator about breakdown, changeover or planned stop | Record cause, responsible owner and next step |
| Hourly production counting varies | Review material, staffing and stops for the same time window | Assign follow-up; check output in the next shift |
| Attendance and deployment differ | Reconcile named attendance with machine assignment | Approve allocation before calculating machine labour cost |
Shift-end WhatsApp summary
At the end of each shift a summary with production counting, manpower gaps and downtime goes to the agreed WhatsApp group. The supervisor opens the evidence, discusses exceptions with the machine operator, aligns staff, confirms stop reasons and records the action for the next shift. Scheduled delivery is configured per group and shift timing.
Two operating requirements the plant agreed to
- Collection SOP. Rotor and stator parts are collected from the designated collection area, not directly from a belt. Direct pickups are flagged with camera evidence; the supervisor reviews the alert, briefs the shift team and reinforces the SOP.
- Conveyor-change notification. Before moving, replacing or changing the belt arrangement: inform Proeffico → share the new layout → adjust monitoring areas → verify counts before routine reporting resumes.
Saved example
AIDA 5 | NIGHT SHIFT SUMMARY
6 Oct, 7 PM – 7 Oct, 7 AM | IST
- Production: 8,005 rotor | 7,892 stator
- Staff below 4: 11h 29m 15s
- Exactly 2 staff: 5h 18m 54s
- Operator area empty: 8h 00m 31s
- Belt 3 inactivity: 4h 16m 33s
Action: verify staffing and operator cover; review stop reasons with the line team.
What it means for inventory and cost
Counted output you can reconcile, exceptions you can see
Reconciliation
The hourly and shift counts come from the camera, not from a manual tally, so they can be set beside the plan, the deployment record and the stop windows for the same time window — and beside approved payroll and allocation records to build machine-wise cost visibility.
Leakage exceptions
Parts are expected to follow one path: belt → designated collection area. Direct pickup from a belt breaks that path and is flagged with saved camera evidence for supervisor review. This is the evidence base for reconciling counted output; the POC does not claim a shrinkage or savings figure.
Labour allocation
Required 4 staff + 1 operator is compared with what the workforce camera observed, and named attendance is reconciled with machine assignment before machine labour cost is calculated. Where observed staff fall short, the first step is to verify where the other assigned staff were deployed — not to attribute a cost.
FAQ
Questions plant heads ask about this deployment
What does VIZO361° count on the AIDA 5 press at Uttam Strips?
Rotor and stator parts as they cross each conveyor belt — Belt 1 (rotor), Belt 2 and Belt 3 (stator). Counts are recorded per hour and per shift. Across the 6–7 October 2026 day and night shifts the system recorded 35,377 parts (9,891 rotor / 9,589 stator by day; 8,005 rotor / 7,892 stator by night), and 76,274 rotor / 70,363 stator across 1–8 October.
How is machine downtime detected without connecting to the press PLC?
From the conveyor camera. A belt is marked DOWN when no part crossing is recorded for 60 seconds, and every interval carries a clear start and end time in IST. It measures production inactivity, not a fault code, so the operator and line supervisor are asked to record the reason for each stop. Belt intervals overlap and are reported belt-wise — they are never summed into a single machine-breakdown figure.
What does manpower monitoring with CCTV report?
The required deployment for AIDA 5 is 4 staff plus 1 operator. The workforce camera reports how long at least 4 staff were visible in the monitored area, how long fewer than 4 were visible, and how long the designated operator area had no person in it. Staff-shortage alerts (for example, required 4 / detected 2) and operator-presence alerts (required 1 / detected 0 for 10 minutes) are raised during the shift. Camera-area gaps identify periods to review; they do not by themselves prove paid absence or its cause.
How does this help with inventory reconciliation and cost in a stamping plant?
The counted output is independent of manual tallies, so management can set it beside deployment, stop windows and the approved payroll and allocation records to build machine-wise cost visibility. Exceptions that break the expected part path — such as parts picked directly from a belt instead of the designated collection area — are flagged with camera evidence for the supervisor to review. The deck does not claim a savings figure; it provides the evidence base for the review.
What does the plant team have to do for the counts to stay reliable?
Two operating requirements: collect rotor and stator parts from the designated collection area rather than directly from the belt (the SOP alert flags direct pickups), and inform Proeffico before moving, replacing or changing the belt arrangement so monitoring areas can be adjusted and counts verified before routine reporting resumes.
Want machine-wise visibility on your press line?
Start with one machine and the cameras you already have: production counting, belt-wise downtime and required-vs-observed manpower from the first full shift.
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