Virtual Part Counter: Reliable Data Even When Your Machines Fall Short

Reliable part counts are the backbone of good decision-making on the shop floor.

Yet for many manufacturers, getting that number right is anything but easy. Some machines have unreliable or inconsistent part counting built in. Others rely on operator input or custom programming to get it right. And when your operators are busy running machines, inspecting parts, and managing changeovers, manual counting is the last thing they should be focused on.

When counts are missing or off, so is everything else:

• OEE numbers don’t add up
• ERP data is out of sync with reality
• Scrap and rework rates can’t be trusted

That’s exactly why we built the MachineMetrics Virtual Part Counter.

Why Traditional Part Counting Falls Short

Part counting sounds simple, until you realize just how many things can get in the way:

• Older or mixed fleets where machine controllers don’t consistently expose part count variables
• Complex jobs that don’t run on the same cycle every time
• Manual configuration or fragile scripts that need constant tweaking
• Human error when operators are asked to track counts themselves

How the Virtual Part Counter Solves It

The Virtual Part Counter uses smart pattern recognition and controller logic to detect parts produced without requiring machine-side counters to be programmed or manually maintained.

Here’s how it works, in simple terms:

• Learns Cycles Automatically: It observes machine signals, like tool changes or program sequences, to learn how your machines produce parts.
• Creates Custom Rules Per Job: Once it understands the pattern for a job, it applies custom cycle rules for every future run automatically.
• Controller-Based Logic: It relies on core controller signals, which are often more reliable than built-in part count variables.
• Dynamic Over Time: Each machine gets a tailored model that can adapt as your production evolves.
• Real-Time + Historical Backfill: The system updates counts live, but also fills gaps if machines go offline or if new jobs are added.

A Practical Safety Net

Whether you run 10 machines or 500, the Virtual Part Counter gives you a consistent, reliable fallback, ensuring that you always know how many parts you’ve made, even when your equipment doesn’t make that easy.

Accurate part counts drive every production KPI that matters. With Virtual Part Counter, you can finally trust the numbers, whether you’re benchmarking OEE, scheduling jobs, or answering a customer’s “Where’s my order?” request.

You shouldn’t have to wonder if your part counts are right. MachineMetrics Virtual Part Counter gives you confidence that they are - across every machine, every shift, every day.