Case - Home appliance | TV packing kitting SOP

Customer background

A TV OEM packing station handles several cases in parallel. Each case needs foam cushioning ×1 and desktop stands ×2 per SOP. Operators walk between bays. Missing foam or a stand means transit damage, returns and brand risk.

Checks rely on eyes in a dark station with low-contrast parts. Parallel cases mix ownership. Shortages show up downstream or at the customer, with no per-case image or count. The plant needed SOP kitting checks with live alerts and a digital trail.

Pain points

Parallel boxes mix up materials

Several cases at once. Operators switch bays fast. Parts are counted to the neighbor case. Misses and false calls happen together.

Dark stations hide missing parts

Low light and contrast. Foam and stands are easy to miss until a later process or unboxing.

No live alert; kitting is hard to trace

No per-case image or count. Shortage has no sound/light. Complaints cannot replay that case.

Solution

Oblique industrial camera, fill light and edge AI. Each case is a numbered ROI. SOP: foam 1/1 and stands 2/2 = OK; shortage marks red and alarms. Multi-frame confirm after occlusion so a passing hand is not NG. Neighbor cases stay in their ROI.

AI packing kitting recognition

Multi-box ROI inspection

Line-side kitting verification

Inference stays on the edge box. Per-case checklist, batch and cumulative counts show on the station board. Images and calls are kept for trace. Bay count is configurable. This solution covers in-case kitting, not part dimensions or taping.