ConductVision Enterprise
ConductVision counts people and forklifts around stations and robot cells, so plant and safety teams see how each station is staffed and where traffic mixes.
20 detectionsConductVision detections on this photo. Photo: Steve Jurvetson from Menlo Park, USA, CC BY 2.0, cropped.
Manufacturing quality control has traditionally depended on statistical sampling and periodic human inspection, methods that miss intermittent defects and scale poorly on high-speed lines. Meanwhile, safety compliance monitoring relies on supervisory walkthroughs that cover only a fraction of shifts. ConductVision's technology can deploy inline visual inspection and continuous safety monitoring that operates at line speed around the clock. Defect detection, PPE verification, safety zone enforcement, and production counting can run simultaneously across multiple camera feeds, providing both quality and safety teams with unified, real-time visibility.
Outcomes
One station runs short while another has spare hands, and the shift report shows only total headcount.
Output drops at the short station, and the line waits on it.
Lines restart late after breaks and shift changes, and the delay hides in daily totals.
Small delays at each restart add up over a week without anyone seeing them.
Forklifts cut through walkways and assembly areas to save a trip around the line.
Mixed traffic in work areas raises the chance of a collision that a rule on paper cannot stop.
Robot cells stop for faults, and an operator has to walk over to reset them.
Each wait for a reset is lost output that the cell's own log may not explain.
Sampling-based QC catches only a fraction of defects, and those it misses become costly recalls or warranty claims downstream. Safety violations like missing PPE or restricted zone breaches often go unrecorded until an incident occurs, leaving EHS teams with incomplete data for root-cause analysis.
ConductVision can run inline defect detection at full production speed, flagging surface flaws, dimensional anomalies, and assembly errors before parts advance to the next station. Simultaneously, PPE detection and safety zone monitoring can operate across the facility floor, generating timestamped compliance records and real-time alerts.
What the model sees
ConductVision detections on this photo. Photo: Greg Walters, CC BY 2.0, cropped.
ConductVision detections on this photo. Photo: Tim Brunauer on behalf of Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ), CC BY-SA 4.0, cropped.
Endpoints
Each endpoint is defined before the pilot starts, with what is counted, its unit and how the results are broken down.
| Endpoint | How it is counted | Unit | Broken down by |
|---|---|---|---|
| PrimaryStation staffing rate | Share of scheduled minutes in which a station has at least its planned number of people. | Unit:% | By:Station, shift |
| SecondaryRestart delay | Minutes from a scheduled start after a break or shift change to the planned crew being in place. | Unit:minutes (median) | By:Station, shift |
| Cell visits | People entering a robot cell's fenced area, counted once per visit with its length. | Unit:visits per shift | By:Cell, hour |
| Forklift zone entries | Forklifts detected inside zones marked for people on foot, counted once per entry. | Unit:entries per shift | By:Zone, hour |
Each pilot measures ConductVision on your own footage against a sample checked by hand, before anyone relies on its numbers.
Headcount agreement
Difference between the ConductVision headcount at a station and a reviewer's count on sampled frames.
people per station (mean absolute difference) · by station, camera
Forklift alert precision
Share of forklift zone alerts that a reviewer confirms in a hand-checked sample of clips.
% · by zone
Missed cell visits
Share of robot-cell visits a reviewer finds in sampled footage that ConductVision did not log.
% · by cell
Capabilities
Boxes each unit on a production line, with defect classes trained on your parts.
Checks hard hats, vests, goggles, gloves and masks against each zone's rules.
Counts and tracks people in each camera view, by zone and hour.
Finds each analog gauge in view, with needle reading calibrated per gauge.
Use cases
High-resolution cameras positioned at critical stations can inspect every unit for surface defects, dimensional deviations, and missing components. Reject signals can be sent to diverter mechanisms automatically, helping prevent defective parts from reaching downstream processes.
Detection models can verify hard hats, safety glasses, gloves, high-visibility vests, and hearing protection across all zones. Non-compliance events can be logged with timestamps and camera locations, providing auditable records for safety reviews.
Multi-step assembly sequences can be verified visually at each station, confirming component presence, orientation, and fastener count. Step-skip errors can be flagged before the unit leaves the station, reducing rework rates significantly.
Virtual perimeters around robotic cells, presses, and hazardous material areas can trigger alerts when unauthorized personnel or unprotected workers enter. Zone breach events can be recorded and escalated according to configurable severity tiers.
Cameras can count units at entry and exit points of each production cell, calculating throughput, reject rates, and cycle times automatically. Data can feed Overall Equipment Effectiveness dashboards without requiring sensor retrofits on legacy machines.
The challenge
Building managers lack accurate, real-time occupancy data, making it difficult to manage capacity limits and allocate resources across floors and zones.
How ConductVision helps
ConductVision can count people entering and exiting each zone, maintaining a live occupancy figure at all times. Dashboards can display current counts against capacity thresholds, and alerts can fire when zones approach or exceed limits, enabling proactive crowd control.
retailhealthcaresmart city
The challenge
Long queues frustrate customers and reduce throughput, yet managers often lack visibility into wait times until complaints arrive.
How ConductVision helps
The platform can measure queue length and estimated wait time at service points in real time. When thresholds are exceeded, alerts can prompt managers to open additional lanes or redirect traffic, improving customer satisfaction and operational throughput.
retailhealthcarelogistics
The challenge
Accurate counting of items, pallets, or vehicles passing through a checkpoint is critical for inventory and logistics but error-prone when done manually.
How ConductVision helps
ConductVision can count objects passing through defined zones with high accuracy, logging timestamps and classifications. This data can feed into inventory systems and operational dashboards, enabling real-time tracking of throughput against targets.
logisticsmanufacturingretail
The challenge
High-value equipment and mobile assets are frequently misplaced or underutilized because manual tracking systems are labor-intensive and outdated.
How ConductVision helps
The platform can detect and track tagged assets as they move through camera views, maintaining a log of last-known locations. Geofence alerts can notify teams when equipment leaves designated areas, reducing loss and improving asset utilization rates.
logisticsconstructionmanufacturing
The challenge
Organizations pay for space they do not fully use, but lack granular data on how meeting rooms, desks, and common areas are actually occupied.
How ConductVision helps
ConductVision can measure utilization rates for defined zones throughout the day, generating heatmaps and time-series reports. Facilities teams can use this data to right-size office layouts, consolidate underused spaces, and justify real-estate decisions with hard evidence.
smart cityretailhealthcare
The challenge
Energy costs rise when HVAC and lighting run at full capacity in empty or lightly occupied areas, and occupancy sensors cover only a fraction of the floor plan.
How ConductVision helps
The platform can provide zone-level occupancy data that integrates with building management systems. HVAC and lighting adjustments can be triggered based on actual presence rather than schedules, reducing energy waste in unoccupied areas.
smart citymanufacturingretail
The challenge
Production lines stall when upstream or downstream stations fall behind, and supervisors may not identify the constraint until output drops significantly.
How ConductVision helps
ConductVision can monitor activity levels at each workstation, detecting idle periods and accumulation of work-in-progress. Bottleneck alerts can direct supervisors to the constraint in real time, and trend data can reveal recurring patterns that inform process redesign.
manufacturinglogisticsconstruction
Related
Counts vehicles and tracks crews and robots in plants and yards.
Tracks staff and protective gear on assembly lines and in clean rooms.
Covered in the Agriculture section, with planning tools and equipment.
Pilot
Tell us about your sites and cameras, and a ConductVision engineer replies with a scoping plan built around the endpoints above.
