VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana sangama, Belagavi, Karnataka-590018

A mini project synopsis on

“Industrial Production Line Counter System”
Submitted in the partial fulfillment of the requirements for award of Degree
Bachelor of Engineering
in
Electronics and communication Engineering
Submitted by
VARUN V R 4GK20EC044
SHWETHA B R 4GK20EC029
VARADARAJ N M 4GK20EC043
MADHUCHANDRA A R 4GK21EC408
Under the guidance of

Prof. M. Shanmugam

Assistant Professor

Department of Electronics and Communication Engineering

KR Pete Krishna Government Engineering college KR Pete-571426

2022-2023
 CONTENTS

Description Page No.

ABSTRACT
1 INTRODUCTION 1
2 LITERATURE SURVEY 2-3
3 PROPOSED WORK 4
OBJECTIVES 5
4 BLOCK DIAGRAM 6-9
5 ADVANTAGES 10
DISADVANTAGES
6 APPLICATIONS 11
REFERENCE 12
 ABSTRACT

Industrial production lines churn out products from raw materials all the time. But keeping these production
lines running effectively is a quite challenging task. There are lots of processes running together which may
invite manual errors. Industrial production lines have different process lines and need manual counting from
time to time to track the product output which can then be passed to next department.

Manually counting the endless supply of products coming out is not possible for a human being. A human
will inevitably loose track at a time. So here we develop an automatic product line counter system to automate
this task.
 Line Counter System

INTRODUCTION

Production counters have been around for as long as manufacturing. Technology enables you to use the
same sensors to do a lot more than simply count production - they can gather valuable production data
about the manufacturing process to help you drive improvement.

Traditionally, production counting systems are used to keep track of the number of items produced in a
plant. However, there is a lot more information, and a lot more useful information, that can be gleaned
from these systems. Count sensors can be linked to OEE software capable of generating 100+ metrics from
those sensor signals. This leads to the distinction between production counters and production monitors.

Every manufacturer needs an accurate count of what they produce. It's a given. However, what is less
understood is that production counters can be used for much more than just counting – they can be used
to drive significant improvements in manufacturing productivity. What do we mean by this? The same
sensors used for counting parts can be used to generate dozens of meaningful and insightful metrics that
provide a comprehensive window into your manufacturing operations.

Consider this:
A Production Counter tells you how much you made,
A Production Monitor tells you how much you made AND it helps you make more.
Using the same two sensors one might use for production counting (Total Count and Good Count) a
production monitor can automatically track Counts, Rates, Cycle Times, Production Times, OEE, Six Big
Losses, TEEP, and Targets.

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LITERATURE SURVEY

In [1], —Product manufacturing could be a tedious method that involves quality management and big
analysis along with its quantity measurement .The classification specifically supports production rate i.e.
quantity factor. It can be achieved by manual labour in industries having either high or low production
rate still it is not possible to make an accurate measurement during the production process. The amount of
any product is a crucial element for estimating the economic growth and financial status of the industry.
This project aims in counting the number of objects placed on a moving conveyor that helps in improving
the demographics of production. The main facet of the project is to automate the process of transportation
of the materials to the respective destinations using sensors and PLC.

In [3], the objective of this research is to decrease the high and ever-increasing demand for electricity. As
the technology improvements preponderate in today’s digital world, we prefer classier and smarter
developments in simple and basic needs of human lives, so this paper gives us a solution to make the
surroundings economic and smarter. To achieve this objective, we can install Automatic Room Monitoring
in every institution, Industries, organization, hall, and House. This design uses infrared ray sensors to
detect the persons entering and leaving the room and monitors the room appliances like fans, light, and air
conditioners. Developing and generating electricity at a small scale is a cumbersome process instead we
consume less electricity and conserve it for sustainable development of energy resources. The proposed
archetypal from the paper can control and monitor the room appliances respective to the people in the
room .

In [4], The area of focus in this project is the development of a system which helps in automatic counting
of the objects passed through the conveyor belt. It saves labour force and time. The system designed is a
prototype for an automatic monitoring and control system for probing objects on a conveyor belt .The
counting system is mainly used for transportation operation in the industry. It also provides real time
information to the operator if the predefined number of the objects is not equal to those received at the
destination point. This system is implemented by using PLC which is the main component along with the

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 Line Counter System

sensors. Our project aims to develop automated counting system for the conveyor belt which is used in
large industries as it has advantages over manual systems. Manual systems are muchcost inefficient as it
includes labour wages which need to be paid time to time. More the labour , more the industry needs
to spend on the wages. Also manual systems are not always accurate. There can be possibility of a mistake
in counting at few events which makes them unreliable. It is also very time consuming as manpower is
slow if compared to any machine designed for specific task.

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PROPOSED SYSTEM

A production counter is a counter system display that keeps track the real-time numbers of your daily
production produced in your plant. Not only just keeping track the production records, it also provides some
useful metrics to help improve the manufacturing operation.

Production counters are important for manufacturers as it provides an accurate count of products produced
in the production floor. As this is part of the system that helps you manage your productions, it helps to
minimize waste or eliminate overproduction issue. Note that, waste incurred cost.

The production counter display shows information such as targeted amount to be produced, actual amount
that has been produced and the balance of the amount that has yet to be produced. Whenever the material
or products goes through the sensor, the information shows on the production counter will be updated
accordingly.

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Line Counter System

OBJECTIVES

➢ Our main objective in this project includes designing and constructing a industrial production line
counter will make a controller based model to count and the number of products at a particular time.
➢ To provide accurate count of products produced from the production floor.
➢ To minimize waste or eliminate overproduction issue.

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BLOCK DIAGRAM

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Components

• Atmega 328 Controller

• Ultrasonic Sensor

• Battery

• LCD Display

• Regulator Circuitry

• Switches

• LED’s

• PCB Board

• Resistors

• Capacitors

• Transistors

• Cables and Connectors

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 Line Counter System

The system makes use of an Atmega Microcontroller with Ultrasonic Sensor, LCD display, power supply,
basic electronics components and PCB board to develop this system. The system allows for a fully
automated industrial product line counting system.

The ultrasonic sensor transmits and receives ultrasonic waves to detect objects. As soon as an object
crosses the sensor path, the sensor receives a response in very short duration indicating an object. This
concept is used to detect a product count.

The data of product count is constantly updated by the atmega controller based on data coming from
ultrasonic sensor. This data is also displayed on LCD display and keeps updating at a fast speed as per
continuous product flow.

Thus the system ensures a smart product counting system for industrial production lines.

The Microcontroller we propose for the system is Arduino (Atmega328). But, there is lot of
microcontrollers available in the market survey better than Arduino.

Arduino is an open-source prototyping platform based on easy-to-use hardware and software. Arduino
boards are able to read inputs - light on a sensor, a finger on a button, or a Twitter message - and turn it
into an output - activating a motor, turning on an LED, publishing something online. You can tell your
board what to do by sending a set of instructions to the microcontroller on the board. To do so you
use the Arduino programming language (based on Wiring), and the Arduino Software (IDE), based on
Processing. Over the years Arduino has been the brain of thousands of projects, from everyday objects to
complex scientific instruments.

A worldwide community of makers - students, hobbyists, artists, programmers, and professionals -

has gathered around this open-source platform, their contributions have added up to an incredible
amount of accessible knowledge that can be of great help to novices and experts alike. Arduino was born
at the Ivrea Interaction Design Institute as an easy tool for fast prototyping, aimed at students without a
background in electronics and programming.

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 Line Counter System

As soon as it reached a wider community, the Arduino board started changing to adapt to new needs
and challenges, differentiating its offer from simple 8-bit boards to products for IoT applications,
wearable, 3D printing, and embedded environments. All Arduino boards are completely open-source,
empowering users to build them independently and eventually adapt them to their particular needs.

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Line Counter System

ADVANTAGES and DISADVANTAGES

Advantages:
This system provides the following advantages:

• Automated Tireless counting

• Keep Count Data Stored as well as Display live count

• No Error probability in counting

Disadvantages:
• Can only be implemented in automated industries.

• Manual working companies requires huge initial cost before implementation of the proposed
system.

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Applications:

1. The production counter is used to calculate the number of finished products during a particular
shift.
2. A production counter tells you how much you made and it helps you to make more.
3. It can be used to drive significant improvements in manufacturing productivity.

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References

[1]. “Industrial Production line Automation Using PLC system”, Department of Electrical and Electronic
Engineering University of Khartoum, July 2009.

[2]. DIY Laser-Counter by www.instructables.com

[3]. “Counting System using Smart Sensors”, Conference paper- November 2016 by Piyadarshini
Mahalingam.

[4]. “Automated Counting System For Industrial Conveyors”, Vrushali Kelkar, Shivani Redkar, Pramila
Volvoikar, Chaya Dhargalkar, Dikshita Shirodkkar ,Electronics and Communication Engineering
Department, Angel Institute of Technology and Design, Assagoa, Goa-India. IJERT, ISSN: 2278-0181
vol.9 Issue 07, July-2020.

[5]. https://nevonprojects.com/industrial-production-line-counter-system/ .

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