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CASE STUDY

Whirlpool – Real-Time Intermediate Inventory Monitoring

We developed a computer vision and sensor-based solution to improve accuracy in intermediate inventory control at Whirlpool’s Rio Claro plant. The system reduced line stoppages, improved stock reliability, and supported operational traceability.

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Industry

Manufacturing & Industrial Operations

Deployment

Real-time stock counting system

Scope

Intermediate inventory monitoring between production stages

Core KPI

>90% stock accuracy vs. ~65–70% traditional manual methods

Overview

As the world’s leading appliance manufacturer, Whirlpool faced challenges in managing intermediate inventory between production processes. Manual counting led to low accuracy, material shortages, and unnecessary line stoppages, reducing efficiency and reliability.

Through the Conecta Startup program, we developed an automated solution to deliver real-time visibility and traceability in stock control.

The Challenge

  • Manual counts were slow and error-prone.

  • Accuracy in intermediate stock was only ~65–70%.

  • Material shortages and excesses led to unplanned production stops.

  • Lack of traceability made audits and reconciliation difficult.

Our Solution

We designed and implemented a real-time inventory monitoring system:

  • Cameras and sensors installed at key points of the line.

  • Computer vision software to identify items and track movements.

  • Business rules to validate entries/exits and avoid duplicate counts.

  • Operational dashboards for operations and planning teams, with alerts, movement audits, and historical data by shift/batch.

  • Light integration with ERP/spreadsheets for reconciliation and executive reporting.

Business Benefits

  • Stock accuracy >90% compared to ~65–70% from manual methods.
  • –18% fewer line stoppages due to reliable counts.
  • Up to 50% faster processes – less manual rework.
  • –30% fewer material shortages with continuous tracking.

How It Works

Sensors & cameras

track items in intermediate stock.

AI & business rules

identify movements and validate counts.

Dashboards & alerts

notify operators of deviations in real time.

ERP integration

ensures reconciliation and reporting.

Technical Highlights

  • Computer vision to detect items and movements.

  • Business logic layer to avoid duplicate counting and errors.

  • ERP integration for stock reconciliation.

  • Dashboards for real-time operational and executive visibility.

Key Results

Achieved >90% stock accuracy.

Reduced production stoppages by ~18%.

Improved operational efficiency by 50%.

Decreased material shortages by ~30%.

See It in Action

  • Real-time stock counting and traceability system.
  • Dashboards with alerts, audits, and history by shift/batch.
  • ERP/spreadsheet integration for reconciliation.

Smarter Inventory Control for Manufacturing Efficiency

Learn how real-time stock monitoring can improve accuracy, reduce line stoppages, and increase operational reliability.

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