{"id":5462,"date":"2025-07-30T07:53:51","date_gmt":"2025-07-30T12:53:51","guid":{"rendered":"https:\/\/dc-digital.com\/wordpress\/?p=5462"},"modified":"2025-07-30T07:53:51","modified_gmt":"2025-07-30T12:53:51","slug":"box-and-package-counter-tracks-planned-actual-and-efficiency","status":"publish","type":"post","link":"https:\/\/dc-digital.com\/wordpress\/2025\/07\/box-and-package-counter-tracks-planned-actual-and-efficiency\/","title":{"rendered":"Package Counter that Measures Efficiency Rate of Production w\/ Area Sensors &amp; Wired Remote for Corporate Food Companies"},"content":{"rendered":"\n<p><a href=\"https:\/\/www.thecampbellscompany.com\/our-food\/campbell-snacks\/\" data-type=\"link\" data-id=\"https:\/\/www.thecampbellscompany.com\/our-food\/campbell-snacks\/\">Campbell\u2019s Snacks<\/a> came to DC-Digital with a specific need\u2014an easy-to-use, high-visibility production counter for their assembly line that could help them monitor performance and stay on track with production goals. In response, we custom-built the <strong>DC-406C-2-EFF-SENS<\/strong>, a dual-sensor counter that provides real-time data on actual vs. planned production output, while also calculating overall line efficiency.<\/p>\n\n\n\n<p>This unit doesn\u2019t rely on a traditional pace-of-production program. Instead, we implemented a <strong>simple 3-button controller<\/strong> with functions for <strong>incrementing, decrementing, and resetting<\/strong> production plans. That level of simplicity allows operators to quickly adapt the system for each shift or production run.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Key Features of the DC-406C-2-EFF-SENS:<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Three-panel display<\/strong>: shows the planned number of units, actual units produced, and efficiency percentage.<\/li>\n\n\n\n<li><strong>Efficiency calculation<\/strong>: Real-time updates up to 200% based on actual vs. planned totals.<\/li>\n\n\n\n<li><strong>Dual photoelectric sensors<\/strong>: Each line on the production floor is equipped with a sensor that contributes to the overall product count.<\/li>\n\n\n\n<li><strong>Sensor range<\/strong>: Adjustable infrared sensors can detect solid objects up to <strong>10 feet away<\/strong>.<\/li>\n\n\n\n<li><strong>Versatile mounting<\/strong>: Each sensor comes with stainless steel mounts and 25 feet of cable. Mounting is straightforward using adjustable tabs and thermal blocks.<\/li>\n\n\n\n<li><strong>4-inch high digits with six-digit capacity<\/strong>: Ensures visibility from a distance and accommodates high-volume tracking.<\/li>\n<\/ul>\n\n\n\n<p>The counter was designed to allow flexibility in how production teams operate. The <strong>planned value<\/strong> can be adjusted at three speeds via the increment button for fast setup. If a value is set too high, the decrement button brings it down at a slower, more controlled pace. A full reset is available to clear the plan and actual counts, recalibrating efficiency in real time.<\/p>\n\n\n\n<p>From a hardware standpoint, the unit is encased in <strong>an all-aluminum enclosure<\/strong> with a <strong>durable acrylic Lexan vinyl front<\/strong>. The high-brightness LED digits ensure clear readability in an industrial setting. The counter is powered using a 24V system, and we provide a <strong>24V power supply for standard 120V wall outlets<\/strong> with each unit, making integration into existing setups seamless.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Designed for the Demands of Modern Assembly Lines<\/h3>\n\n\n\n<p>This counter was built specifically to serve a dual-line environment\u2014ideal for facilities with <strong>two conveyor lines or tracking multiple output streams<\/strong>. Since both sensors contribute to the actual count, users don\u2019t need to micromanage which line contributes what. The system adds up everything automatically and displays the data without any delay.<\/p>\n\n\n\n<p>With just a few button presses, teams can:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Set or adjust their production goals.<\/li>\n\n\n\n<li>Track actual outputs in real time.<\/li>\n\n\n\n<li>Monitor and improve their efficiency, shift by shift.<\/li>\n<\/ul>\n\n\n\n<p>By offering visibility into the gap between planned and actual output, the <strong>DC-406C-2-EFF-SENS<\/strong> helps teams stay accountable and optimize operations. It\u2019s a practical solution that delivers powerful insights without unnecessary complexity.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Built by DC-Digital\u2014Engineered for Customization<\/h3>\n\n\n\n<p>This project highlights our continued commitment to building <strong>custom digital timing and counting systems<\/strong> tailored to each client\u2019s unique workflow. If your team needs production counters, efficiency tracking, or sensor-based display systems, DC-Digital can create a solution that works for your process\u2014not the other way around.<\/p>\n\n\n\n<p><\/p>\n\n\n\n<p><\/p>\n\n\n\n<p>See product: <a href=\"https:\/\/dc-digital.com\/store\/DC-406C-2-EFF-SENS-Package-Box-Production-Counter-w-Efficiency-Diffused-Reflective-Sensor-Input-Actual-Wired-Remote-Controls-for-Setting&amp;Resetting-Planned-Actual-6-4-Inch-LED-Digits-Planned-Actual-3-4-Inch-LEDs-for-Efficiency.html\">DC-406C-2-EFF-SENS<\/a><\/p>\n\n\n\n<p>See tutorial video on <a href=\"https:\/\/www.youtube.com\/watch?v=erYv5WT26y4&amp;t=38s\" data-type=\"link\" data-id=\"https:\/\/www.youtube.com\/watch?v=erYv5WT26y4&amp;t=38s\">YouTube<\/a><\/p>\n\n\n\n<p>Visit our <a href=\"https:\/\/dc-digital.com\/store\/index.php\">home page<\/a><\/p>\n\n\n\n<p><a href=\"https:\/\/dc-digital.com\/store\/contact-us.php\" data-type=\"link\" data-id=\"https:\/\/dc-digital.com\/store\/contact-us.php\">Contact us<\/a> to ask about our customized products!<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Campbell\u2019s Snacks came to DC-Digital with a specific need\u2014an easy-to-use, high-visibility production counter for their assembly line that could help them monitor performance and stay on track with production goals. In response, we custom-built the DC-406C-2-EFF-SENS, a dual-sensor counter that provides real-time data on actual vs. planned production output, while &hellip; <\/p>\n","protected":false},"author":3,"featured_media":5463,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[196,281,207],"tags":[456,509,454,16,205,103,457,458,455,397,282],"class_list":["post-5462","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-counters","category-production-counter","category-scoreboard","tag-actual","tag-area-sensors","tag-assembly","tag-clock","tag-counters","tag-dc-digital","tag-efficiency","tag-photo-optic-eye-sensors","tag-planned","tag-process-counter","tag-production-counter"],"_links":{"self":[{"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/posts\/5462","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/comments?post=5462"}],"version-history":[{"count":4,"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/posts\/5462\/revisions"}],"predecessor-version":[{"id":7140,"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/posts\/5462\/revisions\/7140"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/media\/5463"}],"wp:attachment":[{"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/media?parent=5462"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/categories?post=5462"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/dc-digital.com\/wordpress\/wp-json\/wp\/v2\/tags?post=5462"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}