Real-Time Category-Wise Outbound Crate Counting with SAP ERP Integration at Automobile Manufacturing Facility

The facility manufactured and dispatched products across 10+ categories through a shared conveyor belt system. Every outbound cycle involved crates of different product types leaving the facility - and each category needed to be counted, verified, and recorded separately before the cycle was closed. Manual counting across 10+ categories on a moving conveyor was slow, inconsistent, and error-prone. Staff had to visually differentiate between product categories while maintaining an accurate tally - a task that degraded in reliability as shift volumes increased and fatigue set in. Counts were then manually entered into SAP, introducing a second layer of error and delay between physical dispatch and system record.