Error Reduction in Tapping Operations through Counter-Based Monitoring Systems

Abstract

Manual tapping operations are common in small-scale manufacturing, where precision and consistency directly influence product quality. However, manual processes often lack integrated feedback systems, resulting in missed operations, counting errors, and inconsistent production. This paper presents a low-cost counter-based monitoring system that provides real-time feedback to operators. Using a limit switch, batch counter, buzzer, and indicator lamps, the system tracks tapping cycles, alerts operators at batch completion, and reduces reliance on manual counting. Field implementation demonstrated improved batch reliability, reduced operator fatigue, and higher productivity, making it suitable for MSMEs seeking cost effective automation support.