Verified Outcomes · Real Factories · Measurable Impact

REAL RESULTS FROM
REAL FACTORIES

Every number on this page comes from a live deployment. Measurable, verified outcomes from factories that trusted CountAI to solve problems their teams couldn't crack alone.

95%
Defect Reduction
100%
Count Accuracy
90 Days
Full Rollout
Textile & Apparel

South Asian Textile Group

One of South Asia's largest vertically integrated textile conglomerates, operating 200+ circular knitting machines across 4 plants, producing knitted fabrics for global fashion and sportswear brands.

The Challenge

With 200+ circular knitting machines running at 1,500 RPM across four plants, manual inspection was failing to keep pace. Human inspectors were missing 15–20% of fabric defects at production speed.

  • Customer complaints rising quarter-over-quarter
  • Export orders at risk due to quality inconsistency
  • No standardised grading system across plants
  • Inspector fatigue on 12-hour shifts compounding miss rates
The Solution

CountAI deployed KnitI across all four plants — the world's most advanced AI system for circular knitting inspection.

  • High-speed cameras installed on every machine
  • Intel-based edge compute for on-premise processing
  • Custom AI models trained for 150+ fabric types
  • Automated fabric grading reports generated per roll
  • Real-time alerts and machine halt capability
The Results
  • 95% reduction in defects reaching customers
  • Fabric grading reports auto-generated for every roll
  • Inspection team redeployed to higher-value QC roles
  • Export order rejection rate dropped to near zero
  • Consistent quality across all 4 plants for the first time
95%
Defect Reduction
200+
Machines Covered
150+
Fabric Types
4
Plants Deployed
“The AI catches what our best inspectors couldn't — consistently, at full speed, 24/7.”
— Head of Quality, South Asian Textile Group
Deployment Timeline
1
Pilot
2 weeks — Single machine proof of concept
2
Plant 1 Rollout
6 weeks — Full first plant deployment
3
All 4 Plants
90 days — Complete multi-site rollout
Tyre & Rubber

Major Tyre Manufacturer — MRF

India's largest tyre manufacturer, operating high-volume Tyre Building Machine (TBM) bays with demanding production targets across multiple shifts.

The Challenge

TBM bays were running at unknown true efficiency. Supervisors had no visibility into how time was being spent — blocked, starved, idle, or productive.

  • Production targets consistently missed by 5–8%
  • No data on blocked/starved/idle time per operator
  • Root causes of downtime invisible to management
  • Subjective shift reports with no granular time data
The Solution

CountAI deployed a Man-Machine IoT system using existing CCTV cameras — no new hardware required on the production floor.

  • AI classifies every second of every operator shift
  • Four activity states tracked: S1 (productive), S2 (blocked), S3 (starved), S4 (idle)
  • Real-time dashboards for supervisors and plant managers
  • Automated shift-end reports with time breakdowns
The Results
  • 15–30 minutes recovered per bay per shift
  • Root causes identified: material delays, tool changeover gaps
  • 1–3% output uplift per bay measured
  • Data-driven shift scheduling implemented
  • Plant-wide rollout approved after PoC results
15-30
Minutes Recovered / Bay / Shift
5-8%
Production Gap Closed
1-3%
Output Uplift Per Bay
0
New Hardware Required
“We were sceptical about a 6-week trial. The data spoke for itself — we saw problems we didn't know existed.”
— Plant Manager, MRF
Deployment Timeline
1
Free PoC
6 weeks — Zero-cost proof of concept
2
Results Presentation
Data-driven ROI review with leadership
3
Plant-Wide Rollout
Decision to deploy across all TBM bays
Healthcare & Packaging

US Healthcare Packaging Company

A leading US pharmaceutical packaging company running high-speed packaging lines for regulated healthcare products, where count accuracy is both a compliance requirement and a cost driver.

The Challenge

High-speed pharmaceutical packaging lines were consistently overcounting — putting 2–3% excess product into every box, costing millions annually in product giveaway.

  • 2–3% overcount (excess product per box) across all lines
  • Millions lost annually in product giveaway
  • No real-time count verification at production speed
  • Manual spot-checks catching issues only after the fact
The Solution

CountAI deployed an AI-powered counting system with cameras at each packaging station, verifying piece counts in real time at full line speed.

  • High-resolution cameras at every packaging station
  • Real-time AI piece count verification
  • Instant alerts on count deviations
  • Full integration with existing line PLCs
  • Dashboard with per-line, per-shift count analytics
The Results
  • 3% excess packaging eliminated entirely
  • 100% count accuracy achieved for the first time
  • Millions saved annually in product giveaway
  • Regulatory compliance strengthened with full audit trail
  • Expanded to 5 packaging lines total
100%
Count Accuracy
3%
Excess Eliminated
5
Lines Deployed
$M+
Annual Savings
“For the first time in our facility's history, we achieved 100% count accuracy at full production speed.”
— VP of Operations, US Healthcare Packaging Company
Deployment Timeline
1
Pilot Line
3 weeks — Single line proof of concept
2
Validation
Results verified against manual counts
3
4 Additional Lines
60 days — Expanded across facility

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For Your Factory

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