EnCata engineered an AI-powered tool tracking system which combines 5S boards with machine vision to monitor tool usage in real time. Integrated with ERP/CRM software, it improves accountability and reduces losses. Our team took the project from concept through to a working IIoT solution.
One of the most common and annoying problems in manufacturing and service companies is tools going missing.
To address this, methods like LEAN and Six Sigma use 5S shadow boards. These boards help track tools by showing where each one should be placed and alerting workers when something is missing, like at the end of a shift.
However, in workshops with multiple users, 5S boards often don’t prevent tools from being misplaced or taken without being returned.
Challenges
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Approach & Solution
To fix the issue of missing tools, EnCata came up with a smart combo: machine vision (MV) paired with standard 5S boards. A CMOS camera linked to a cloud-based AI system keeps an eye on whether tools are in their spots.
The team built a neural network (NN) that processes live camera feeds. The NN was trained with supervised learning to recognize tools, even accounting for camera lens distortions.
Users check tools in and out by scanning a QR code tied to their ERP/CRM account. If someone takes a tool without checking it out, the system triggers an ‘Andon’ alarm — sound and visuals — to call it out. The neural network identifies exactly which tool is missing, giving you a double layer of control: visual and AI.
Need help developing a custom AI/IoT tracking solution? Feel free to get in touch with us. We will supply you with a precise estimate promptly!
The application of this technology extends beyond tool tracking. It can be adapted for inventory management in industries such as automotive and aerospace. For instance, it can automate Kanban stock monitoring, triggering alerts for component procurement and aligning seamlessly with LEAN workflows.
Results and Benefits
The solution makes it easier to track tools in workshops, saving time and reducing hassle. The AI/ML software connects with the ERP system to manage inventory and provides clear analytics on how tools are being used. It’s a practical system that can also be adapted for other object recognition tasks.
5 months
project duration
2,000 mm
max width of the 5S board
5 mm
the smallest tool size
Our Role
Machine vision service development
Backend software development
Database development
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