KOMPASS™ AI counts each unit, sorts it by SKU, size, and condition, and logs the result as parts travel the conveyor. US plants and distribution centres stop recounting cartons before invoicing.
Many US plants still use a counting scale for product counting and leave sorting to whoever works the line that shift. Both hurt order accuracy, and neither shows its errors until a customer opens the carton.
KOMPASS™, Jidoka's AI Product Inspection system, works as an automated part counting and sorting system for US plants and DCs. Paired with Modular Vision Infrastructure, it identifies each unit in motion, counts it, and classifies it without a standalone sorting machine, and it records what went into each shipment.
See it running on your line
Tell our engineers what gets past your reject gate today and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertSee it running on your line
Tell our engineers what you fill and how fast and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertSee it running on your line
Tell our engineers your size bands and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertSee it running on your line
Tell our engineers which SKUs get mixed up and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertSee it running on your line
Tell our engineers how your batches are tracked and they will walk you through implementation, timelines and cost for your line.
Learn More - Talk to our expertCounting and sorting run on the cameras you already have on your line. No pilot line, no new hardware to install. We have mapped this deployment before, which is what makes it fast now.
We walk your line, confirm camera and lighting coverage at the count and sort points, and scope the SKUs, sizes and reject criteria.
The model trains on your own SKUs, sizes and reject criteria, with 20 samples per defect, not a generic product library.
Counting runs in shadow mode beside your current counts, then goes live on your reject gate and dispatch records once it agrees with them. Deployment takes 6–8 weeks.
Bring your fastest line and the SKU pair that gets mixed up. We will scope a pilot on your line.
Comparison
How the count is made
By hand, or by eye
Total mass divided by a unit weight
Every unit detected and counted
Mixed or irregular parts
Slows to a crawl
Tolerance errors compound
Counted by what each part is
Telling SKUs apart
Depends who is on shift
It cannot, weight is weight
By type, size, shape and condition
Rejecting what does not belong
Pulled off by hand, later
Not its job
Ejected inline, inside the dwell time
Hardware
Trays, scales and tally sheets
A counting scale per line
Runs on the cameras you already have
Traceability
A number written on a docket
A total, with no record per unit
A digital audit trail per dispatch
First-Time-Right
Hope
Right on average
Right the first time, every shift
From noodle multipacks, where package counting with vision AI confirms each sachet, to biscuit lines, these deployments show an automated part counting and sorting system checking and rejecting at production speed.
High-speed biscuit inspection with automated quality control:
Labelled bottle inspection with AI vision system and modular hardware:
Yes, for mixed or light parts. A counting scale estimates quantity from total weight, and a heavier batch of caps or a damp carton skews the number. A vision counting system sees every unit separately, and weight never enters the count.
Yes. KOMPASS™ tunes detection to the shape of each part, which lets washers, O-rings, and small fasteners count correctly even when they touch or stack.
Each variant gets its own learned features, from logo placement to cap colour. When a stray SKU appears, KOMPASS™ flags it on the spot.
It does both. The count feeds your shipping records, and automated sorting drives your existing diverters or robotic sorting cells.
No. A dedicated sorting machine, such as an optical colour sorter, handles bulk streams like grain or recycled plastic. KOMPASS™ adds automated sorting to the line you already run and handles individual products one at a time.
Yes. Many big-box chains in the United States fine suppliers for short or mixed shipments. Count verification at pack-out gives you proof, case by case, when a chargeback lands.
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