Production line downtime monitoring with cameras

Line downtime seen in minutes, not in write-offs

Cameras watch zones on the line, and the model sees whether people are there and whether product is moving on the conveyor. If a zone stays empty past the threshold, the shift supervisor gets an alert and a light-and-sound beacon goes off on the floor. Everything runs on an edge unit in the workshop, no cloud.

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How downtime hides until the end of the shift

  • The belt stopped, the operator stepped away. The dough over-proofed and the batch was written off — and you learned about it from the write-off report.
  • The CCTV monitors sit in the supervisor’s office. Nobody watches them: the supervisor is out on the line.
  • The cause of downtime is reconstructed from memory: «I think we were waiting for raw materials». Nobody rewatches the footage.
  • The workshop is humid and full of flour dust. Ordinary office cameras do not last long there.

What changes after launch

  • 01The shift learns about downtime within minutes
  • 02No one has to watch a monitor: the beacon goes off
  • 03A downtime log by zone and shift instead of guesses

How the system works

  1. 01

    We record the line

    For 1–2 days we film real work: where people stand, how product moves, where metal glares and flour hangs in the air. That footage tells us how many cameras are needed and where.

  2. 02

    Cameras built for the floor

    Industrial IP67 cameras, PoE power, RTSP video. If your existing cameras already see the right zones, we use them.

  3. 03

    Zones and timers

    A YOLO-based model sees people and product in marked zones. The rule is written in your supervisor’s words: «nobody in zone A for three minutes and nothing moving on the belt — that is downtime».

  4. 04

    The shift is alerted

    The event goes to the shift supervisor in Telegram and a beacon goes off on the floor. Nobody needs to watch a monitor to know the line has stopped.

  5. 05

    Shift log on a local screen

    A local dashboard with zone statuses, the downtime log and a siren reset button. The supervisor sees how long each zone stood idle.

  6. 06

    Calibrated on a live shift

    We tune thresholds in the workshop so the siren does not go off when someone steps away for 10 seconds.

Which scale is yours?

One task, three different projects. Pick the one that looks like you and press “I want this” — your request arrives tagged, and we send an estimate in 1–2 days.

Small business

common start

One line where downtime costs the most, and a supervisor who is the last to hear about it.

What we build

  • 1 line, 2–4 IP67 cameras
  • GPU edge unit right in the workshop
  • Zones, timers and thresholds for your line
  • Telegram alerts and a beacon on the floor
  • Local shift supervisor dashboard
Integrations
Telegram, beacon relay, your IP cameras over RTSP
Where it runs
Edge unit on site: video never leaves the workshop
Timeline
Guideline: 3–6 weeks for the pilot, including line recording and calibration

Mid-size business

common start

Several lines or workshops, and the plant manager needs to compare their utilisation instead of hearing an explanation for each.

What we build

  • Several lines and workshops in one system
  • Supervisors tag the cause of downtime right in the dashboard
  • Line utilisation by shift — a summary for management
  • Events passed to your ERP (1C) or MES
  • Support contract: retraining when the product or camera angle changes
Integrations
ERP (1C), MES, Telegram, line cameras
Where it runs
Edge units in workshops and a server on site
Timeline
Guideline: 2+ months, starting with a pilot on one line

Enterprise

Several plants, your own video surveillance system and a security team that signs off on every connection.

What we build

  • Shared downtime rules across all sites
  • Integration with your VMS: we use streams from existing cameras where the angle works
  • Roles and permissions: a supervisor sees their line, management sees all
  • Event and action log for audits
  • Service under an SLA
Integrations
VMS, MES, ERP (1C), corporate systems
Where it runs
Your servers or a closed perimeter: video never leaves it
Timeline
Guideline: 3+ months, starting with a pilot at one site

Pilot from RUB 500,000. Beyond that we price by task and hours.

Questions

Do we need new cameras?

Not always. If a camera sees the right zone and provides an RTSP stream, we work with it. For a humid, flour-filled workshop we usually install industrial IP67 cameras: office ones fail quickly there. Hardware is a separate line in the estimate.

Will the siren go off every time someone takes a break?

We tune thresholds on a live shift: how long a zone can stay empty without consequences and what else has to be happening at the same time. Someone stepping away for 10 seconds is not downtime.

Does video go out to the internet?

No. The model runs on the edge unit in the workshop and the dashboard is on your local network. Only the alert text goes out, if you choose Telegram. The system does not recognise faces: it only cares whether someone is in the zone.

How much does a pilot cost?

From RUB 500,000. We give the exact figure after a 1–2 day assessment: how many cameras, whether new ones are needed, workshop conditions, who handles installation. Beyond the pilot, cost depends on the task and hours.

More in this area

A quote in 1–2 days

Name the process that eats time. You get a pilot range, not a 40-slide deck.

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