CountWONDER® is a smart production monitoring and OEE (Overall Equipment Effectiveness) system designed for printing and packaging industries. It captures real-time machine data to track production, downtime, and performance — helping factories improve productivity, reduce waste, and make data-driven decisions.
It automatically counts machine output, measures running efficiency, downtime, and generates detailed shift and performance reports. The system transforms raw production data into actionable insights for management and operations teams.
While optimized for the printing and packaging sector, CountWONDER® is compatible with any discrete manufacturing environment — including labels, cartons, pharma inserts/outserts, corrugated boxes, and flexible packaging.
Traditional counters only record quantities. CountWONDER® goes beyond counting — it analyzes speed, runtime, stoppages, operator efficiency, and calculates OEE in real time. It also provides visual dashboards, shift reports, and intelligent alerts.
OEE (Overall Equipment Effectiveness) is the key metric for measuring how efficiently a machine is utilized. CountWONDER® calculates OEE based on Availability × Performance × Quality, using live data from machine sensors.
Yes. With CountWONDER® AI Insights, the system can identify recurring issues, analyze downtime patterns, and suggest preventive actions — enabling predictive maintenance and smarter factory operations.
Yes. CountWONDER® WhatsApp Reporting automatically sends production summaries, downtime alerts, and shift reports directly to your mobile, ensuring instant visibility even when you’re away from the shop floor.
It connects via sensors (retro-reflective, contrast, or inductive) or through the machine’s PLC/embedded output. The captured signals are processed by CountWONDER® AIoT hardware and transmitted securely to the cloud or local server.
Yes. CountWONDER® can be retrofitted to virtually any machine — including old mechanical or semi-automatic systems — using smart sensors and an interface module.
Yes. It can be integrated with existing ERP/MIS platforms via API or data export options, ensuring a seamless flow of production and performance data.
All data captured by CountWONDER® is securely stored on the cloud (if subscribed to the cloud option). Alternatively, customers can opt for on-premise (local server) deployment where data remains within their factory network.
Absolutely. The system supports both single-machine installations and plant-wide multi-machine networks. The CountWONDER® Mesh architecture allows scalable deployment across multiple production lines.
A standard single-machine installation typically takes 1–2 hours, including sensor calibration and testing. Multi-machine setups can be completed within a few days depending on site size.
Minimal training is needed. CountWONDER® dashboards are intuitive and visual. Operators can start using it effectively after a short demonstration session.
Yes. It automatically generates shift-wise, daily, and monthly reports in Excel or PDF format — including production count, downtime, OEE, and operator performance.
Internet is required only for cloud synchronization and remote viewing. The system continues to capture data even if the internet is temporarily unavailable and uploads it once reconnected.
CountWONDER® offers remote and on-site support options. Our team provides setup assistance, software updates, and technical troubleshooting as part of the annual service agreement.
Yes. The system can be tailored for specific production setups — such as job card tracking, client-based reporting, or machine-type-specific dashboards.
Yes. CountWONDER® OEM offers embedded intelligence for machine builders, allowing them to deliver “OEE-Ready” machines with smart analytics built in.
You can request a demo or quotation by visiting www.countwonder.com or emailing info@countwonder.com. A representative will connect with you to schedule a live demo or on-site presentation.
CountWONDER® AI Insights transforms raw production data into meaningful intelligence predicting issues, optimizing performance, and helping factories achieve operational excellence.
CountWONDER® OEE Insights helps factories maximize efficiency and minimize downtime through real-time OEE tracking and continuous improvement analytics.
CountWONDER® OEM enables machine manufacturers to embed OEE-ready intelligence directly into their equipment.
Yes. When integrated with PowerWONDER, it can also monitor power consumption, helping correlate energy usage with machine performance and efficiency.
Yes. CountWONDER® AI learns from historical data to identify root causes and recommend corrective actions for recurring issues enabling predictive maintenance.