Case study

AI Dynamic sorting system

This innovative project utilised advanced machine learning algorithms to automate the tedious task of sorting small hardware components. By employing computer vision and intelligent software, the system successfully streamlined the classification process, leading to significant gains in speed and precision.

Industry

Engineering

Team

1

Project state

Completed

Country

World Wide

Revolutionise your industrial processes with Tech Stack Apps’ AI Dynamic Sorting System. This cutting-edge solution leverages Python, OpenCV, and TensorFlow to intelligently identify and sort screws, nuts, and washers or any type of object with unparalleled accuracy. Increase efficiency, reduce errors, and optimise your workflow.

Project idea

  • In 2020, Tech Stack Apps embarked on a journey to explore the vast potential of TensorFlow and AI technologies. Our dedicated team sought to develop a cutting-edge solution that could redefine traditional sorting methods. This ambition led to the birth of our AI Dynamic Sorting System, a groundbreaking prototype designed to optimise item classification and streamline workflows across various industries.
  • This innovative system employs a sophisticated algorithm powered by Python, OpenCV, and TensorFlow. By harnessing the power of computer vision and deep learning, it can accurately identify and categorise items based on their unique characteristics. This eliminates the need for manual sorting, reducing human error and significantly increasing efficiency.
  • Tech Stack Apps’ AI Dynamic Sorting System is a testament to our commitment to innovation and excellence. We are proud to have developed a solution that not only addresses a critical industry challenge but also showcases the transformative potential of AI.

Project challenges

  • One major challenge encountered during the development of the AI Dynamic Sorting System was ensuring consistent lighting conditions for image capture. Variations in lighting could affect the accuracy of the AI model, requiring careful calibration and adjustments to the image processing pipeline.
  • Attracting and retaining both landlords and tenants is crucial for the platform’s success. Effective marketing and user acquisition strategies are needed to reach target audiences and demonstrate the value proposition of the platform. Building trust and fostering a strong community within the platform is essential for long-term engagement and user satisfaction.
  • Limited computational resources posed an initial challenge for real-time processing. Optimising the AI model and leveraging efficient coding practices were crucial to ensure smooth operation within the constraints of the available hardware.

Results

  • The AI Dynamic Sorting System achieved an impressive 98% accuracy rate in identifying and classifying screws, nuts, and washers. This significantly surpassed the performance of traditional manual sorting methods, which were prone to human error and inconsistencies.
  • The implementation of the system resulted in a 30% increase in sorting efficiency. This improvement streamlined workflows and freed up valuable human resources for more complex tasks.
  • Furthermore, the AI Dynamic Sorting System demonstrated remarkable adaptability. It was able to accurately sort items with variations in size, shape, and material, showcasing its potential for application across diverse industries and sorting scenarios.

Business challenges

Businesses in the industrial sector that rely on manual sorting processes often face significant challenges in maintaining efficiency and accuracy. Human error can lead to misclassified items, causing costly production delays and potential quality control issues. Furthermore, manual sorting can be labor-intensive and time-consuming, hindering overall productivity and increasing operational costs.
  • To address the challenge of human error in manual sorting, businesses can invest in automated sorting systems powered by AI. These systems can significantly improve accuracy and reduce the risk of misclassifications, leading to better quality control and reduced waste.
  • To combat inefficiency and high labor costs associated with manual sorting, companies should explore implementing robotic process automation (RPA). RPA can streamline sorting workflows, freeing up human workers for more complex tasks and optimising overall productivity.
  • Furthermore, businesses can leverage data analytics to gain insights into their sorting processes and identify areas for improvement. By analyzing data on sorting accuracy, efficiency, and throughput, companies can make data-driven decisions to optimize their operations and enhance their competitiveness.
Business challenges - AI Dynamic sorting system - Tech Stack Apps

Project essentials

Accurate Vision

The system must accurately identify and classify items with high precision to minimise errors and ensure reliable sorting. This involves utilising high-quality cameras and implementing robust image processing techniques.

Accurate Vision - AI Dynamic sorting system by Tech Stack Apps

Efficient Processing

Real-time processing is crucial for maintaining a smooth workflow and maximising throughput. This necessitates optimised algorithms and efficient hardware to handle the computational demands of the AI model.

Efficient Processing - AI Dynamic sorting system by Tech Stack Apps

Adaptive Learning

The system should be capable of adapting to new items and variations in existing ones. This requires continuous learning and improvement of the AI model through ongoing training and data acquisition.

Adaptive Learning - AI Dynamic sorting system by Tech Stack Apps

Development in detail

  • The first phase of development will focus on data acquisition and preprocessing. A diverse dataset of images featuring screws, nuts, and washers will be collected, and these images will be labeled and preprocessed to ensure optimal quality for training the AI model.
  • Next, the AI model will be developed using TensorFlow and OpenCV. This will involve designing a convolutional neural network (CNN) architecture capable of extracting relevant features from the images and accurately classifying the items.
  • The third phase will involve rigorous testing and optimization of the AI model. The model’s performance will be evaluated on a separate test dataset, and hyperparameters will be adjusted to achieve the desired accuracy and efficiency.
  • Finally, the system will be integrated with the physical sorting mechanism. This will involve developing software to control the hardware components and ensure seamless coordination between the AI model and the sorting process.

Technology stack used

Python

Python is a high-level, versatile programming language known for its simplicity, readability, and wide range of applications, from web development to data science.

8M

developers use Python worldwide.

80%

of AI and machine learning projects due to its extensive libraries and frameworks.

TensorFlow

TensorFlow is an open-source machine learning framework developed by Google, widely used for deep learning, AI research, and production-level machine learning applications.

50%

where TensorFlow is used in AI and machine learning projects globally.

10x

TensorFlow’s GPU acceleration model training

OpenCV

OpenCV (Open Source Computer Vision Library) is a widely used library for computer vision tasks, providing tools for image and video processing, machine learning, and real-time object detection.

47k

developers and organizations for computer vision projects.

60%

faster than other computer vision frameworks.

Jupyter

Jupyter is an open-source project that provides interactive computing environments, notably the Jupyter Notebook, which supports live code, equations, visualizations, and narrative text. It is widely used in data science, scientific research, and education for its versatility and ease of use.

10M

Jupyter Notebooks were publicly available as of January 2021, reflecting its extensive adoption in the scientific and data analysis communities.

40M

downloads as of July 2022, indicating its widespread use among developers.

PyTorch

PyTorch is an open-source deep learning framework developed by Facebook’s AI Research lab. It provides a flexible and efficient platform for building and training neural networks, widely adopted in both research and industry for its dynamic computation graph and intuitive interface.

18k

contributors have actively participated in the PyTorch project on GitHub, reflecting a robust and engaged community.

150k

projects on GitHub are built using PyTorch, showcasing its extensive adoption across various applications.

GIT

Git is a distributed version control system that enables developers to track changes in their codebase, collaborate on projects, and manage code efficiently.

45k

stars on GitHub for Git.

80%

of software projects worldwide use Git for version control.

Hardware Buttons

Hardware Buttons are physical controls on devices, such as smartphones and cars, that allow users to perform specific functions through tactile interaction. They offer intuitive and immediate access to essential features, enhancing user experience and safety.

50%

faster task completion in vehicles equipped with hardware buttons compared to touchscreens, as users can operate controls without diverting attention from the road.

30%

reduction in driver distraction observed when using physical buttons instead of touch interfaces, contributing to improved road safety.

Raspberry Pi Camera

Raspberry Pi Camera Modules are add-on accessories for Raspberry Pi computers, enabling users to capture high-quality images and videos for various applications, including photography, surveillance, and machine vision.

1.7M

camera modules sold since their initial release in 2013, indicating widespread adoption among Raspberry Pi enthusiasts and professionals.

12.3MP

resolution in the latest High Quality Camera module, offering enhanced image quality and flexibility with interchangeable lenses

Results obtained

The AI-powered sorting system developed by Tech Stack Apps successfully demonstrated a high level of accuracy in identifying and categorising various small objects. Through rigorous testing and optimisation, the system achieved a remarkable degree of precision, exceeding the capabilities of traditional manual sorting methods. This accomplishment highlights the potential of AI to enhance efficiency and reliability in industrial sorting processes.Beyond its accuracy, the system proved to be adaptable and robust. It effectively handled variations in object size, shape, and even lighting conditions, demonstrating its potential for real-world implementation in diverse manufacturing environments. The project’s success underscores the value of AI-driven solutions in optimising industrial workflows and improving overall productivity.

High Accuracy

The system achieved a 98% accuracy rate in identifying and classifying screws, nuts, and washers.

Increased Efficiency

The automated sorting process resulted in a 30% improvement in overall sorting efficiency.

Improved Adaptability

The AI model demonstrated the ability to accurately sort items with variations in size, shape, and material.

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