AI-powered 5S tool boards use machine vision to track tool availability, ensuring no item is missing or checked out in the workshop. This system can be adapted to other industries that require continuous object recognition.
Industry:
Services:
TRL:
1 → 9
Project duration:
10 months
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.
REST API
Gradle software build tool
Spring Boot framework
MongoDB database
Netty client-server framework
Docker software platform
Java 11
CMOS camera
Ubuntu server
QR codes
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.
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.
of development
max-width of the 5S board
the smallest tool size
