Closing the Accuracy Gap: How City Pallets Found 10% More Production
City Pallets discovered that manual counting was under-reporting production by 8-12%. PalletVision gave them accurate, per-station counts and the data to optimize their nailing and trim saw operations.
8-12%
Under-Reported Production Found
6
Stations Monitored
100%
Manual Data Entry Eliminated
3 days
Time to Deploy
The Challenge
What City Pallets Was Facing
City Pallets suspected their manual counting process was inaccurate but had no way to verify it. Board counts from trim saws were estimates at best, and nailing machine output was tracked with tally marks on whiteboards. The operations team needed reliable per-station data to make scheduling and staffing decisions, but their ERP showed numbers that did not match what they saw on the floor.
The Solution
How PalletVision Helped
PalletVision cameras were deployed at 6 stations across nailing machines and trim saws. The AI system was calibrated to each station's layout, counting finished pallets and cut boards with 95%+ accuracy. Data was piped directly into PalletConnect ERP, replacing all manual count entry. Historical trend views gave managers shift-by-shift comparison data for the first time.
The Results
What Changed
- Discovered 8-12% under-reporting in manual counts, revealing significant hidden production
- Per-station, per-shift analytics enabled data-driven scheduling for the first time
- Trim saw board counts went from rough estimates to exact numbers per saw
- All manual data entry for production reporting was eliminated
- Managers now use trend data in weekly operations reviews to set targets and track improvements
“The accuracy surprised us. We thought manual counting was close enough, but PalletVision showed us we were off by 8-12% on our busiest lines. That is real money.”
David Chen
Plant Manager, City Pallets
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