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Home Expertise Library Stories Achieve Accurate Counting Results

Achieve Accurate Counting Results

When Choosing a Counting Solution in Manufacturing, Consider Three Key Factors

High-piece weight variations posed significant problems for an automotive supplier. Deliveries with the wrong number of products were rejected which led to higher delivery costs. By switching to a dedicated counting solution, the supplier regained their customers' confidence.

The accuracy of parts counting is influenced by multiple factors, but three main factors help suppliers achieve accuracy:

-Knowing parts' weights and their deviation 

-Selecting the right scale

-A calibration plan

Achieve Accurate Counting Results
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Consider Parts Weights and Deviation

Consider Parts Weights and Deviation

A critical consideration in any counting process is accurately counting parts that vary greatly in weight. The deviation in piece weight for each part can be measured using the standard deviation, with high-precision parts having an average piece weight deviation of around 0.5%. 

The impact of average piece weight and deviation on counting accuracy is significant. The higher the standard deviation, the greater the resulting counting error. Additionally, smaller average piece weights require higher counting resolutions to achieve accurate results. 

Select the Right Counting Scale System

To start counting with a scale, the average piece weight first needs to be determined. Industrial counting scales can store the average piece weight in its memory. To do this, first weigh ten sample parts and press the sample 10 (or reference 10) key. Now the scale will store the average piece weight to its internal memory, a crucial key to achieving accurate counting results. Making a mistake here translates to big errors throughout the counting process.

Modern weighing indicators offer a clear and error free prompt interface to guide operators through the counting process. Indicators with touch screens and smart keys allow to adapt the indicator to your unique needs and support easy data exchange between devices including printers, bar code scanners or your MES solution. 

Benefits of a Calibration Plan

Benefits of a Calibration Plan

Not only is it important to select the right equipment, but installing it correctly and getting operators trained is paramount to putting in place a maintenance and calibration plan. Even though industrial scales are designed to withstand harsh manufacturing environments, they must be periodically tested and maintained. Proper scale calibration is especially important when operating a two-scale system. If the sample and counting scale are not periodically calibrated, chances are the counting results are wrong. 

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