Kamax Replaces Manual Counting with Real-Time Production Data Using Kenar-Bulut Sensors

[Erkan Teskancan]

## Kamax Digitalizes Manual Counting in Production with Edge-to-Cloud Sensors

For years, manufacturers have struggled to transform what happens on the factory floor into usable information for making better decisions. At the core of this problem is the inability to capture and contextualize accurate data in a timely manner and present it to support critical decisions.

Often, production counts, order status, and inventory levels are still obtained from handwritten records, spreadsheets, or daily reports. However, this information often does not reflect the current situation and leads to delays in performance measurements.

In high-volume production companies like automotive supplier Kamax, part counting poses a significant challenge. Kamax produces high-strength bolts and precision parts; weight measurement or manual counting methods are used to estimate the unit count. However, when these methods are applied across numerous machines and shifts, they result in time loss and data inconsistency.

### Kamax's Approach to Production Data Collection

To move away from manual data collection methods, Kamax initiated a technology-based transformation. They redefined the problem not just as "How can we count faster?" but as "How can accurate and real-time information be made available where needed?" This made the importance of data collection a strategic issue.

### Disadvantages of Camera-Based Counting

Initially, Nexineer Digital (Kamax's digital unit) planned to count parts by collecting image data with cameras. However, the challenging conditions of the production environment, the need for special positioning for camera mounting, suitable lighting, and continuous cleaning made this option costly and difficult. Furthermore, Kamax's diverse types and generations of cold-forming machines limited the applicability of a standard camera system.

### High-Speed Part Detection with Sensors

Nexineer evaluated different sensor technologies and opted for a high-resolution light grid sensor. These sensors create a physical light curtain that each part passes through after exiting the machine, and each beam interruption is counted as a part.

• Sensors are connected to IO-Link master devices via IO-Link.
• These devices send data to an edge gateway, which is responsible for preprocessing and transmitting the data.
• The light grid can be easily adapted to different machine types and generations.

### Kamax's OT-to-Cloud Bridge

A bridge was established between OT (operational technology) and the cloud infrastructure to transmit counting data from the primary data source to the cloud in a structured manner. Belden's CloudRail platform, with AWS IoT Greengrass and IO-Link integration, allows data to be centrally managed and updated, and prepared for analysis in the cloud.

• The edge gateway collects real-time data and packages information to reduce unnecessary data transmission.
• Data transmitted to AWS IoT Core is used in analyses such as order progress and OEE performance indicators.
• CloudRail automatically detects sensors, provides secure connections, and enables central management.

### A New Era in Production: Automated Counting and Increased Efficiency

Thanks to automatic and continuous data tracking instead of manual weighing and counting, operators' workload decreased by 2.5%–3.5%, freeing up time for more valuable tasks. Planners can now align production more closely with customer demands.

### Investing in the Future and Scalability

For Kamax, the sensor-based standard solution is reusable across different machines, reducing maintenance and expansion costs. Standard interfaces and data models ensure easy integration with new devices and applications.

### 3 Important Lessons from Kamax for Modernization Projects

• Prioritize the most critical tasks. Daily pain points form the basis for digitalization investments.
• Emphasize privacy. Using process data instead of images accelerates adoption.
• Prioritize standardization. Create scalable platforms with uniform hardware and interfaces.

Kamax's example shows that when you develop repeatable methods that consider the realities of the factory floor, continuous improvements in visibility, performance, and flexibility can be achieved.