Real-time production monitoring for an export-focused food manufacturer
The challenge
Production losses were estimated at several million US dollars. But the client only learned about them at the start of each month, once the previous month's spreadsheet reports had been reconciled. By then it was far too late to act.
What we did
After a requirements analysis and functional specification, we assembled a virtual project team, including a specialist industrial IoT partner, and built a vendor-neutral monitoring platform:
- One open standard: sensors and scales from several manufacturers, some decades old, were brought onto one open protocol, so the client isn't tied to any one vendor.
- Live data on site: mass flow, concentration, turbidity, conductivity, pH and temperature on every line are recorded at second intervals and stored in real time on the client's own server.
- Dashboards per sensor: every measurement has a red tolerance band. If it's breached, the system automatically sends SMS alerts to the responsible people, within seconds.
- An early-warning band: our own addition, a narrower yellow band that warns before a value reaches the critical zone, so the team can act before a loss occurs.
- Management reporting: consolidated figures in SQL Server and Power BI.
- Room to grow: the platform is designed for expansion to 80–100 sensors.
The result
The system was delivered to specification, on time and on budget. Instead of finding losses weeks after the fact, the client now sees problems as they develop and can step in before they cost money. Management has reliable, consolidated figures instead of month-end spreadsheets. With all intellectual property handed over, the client then took the system in-house, fully independent of any vendor, including us. It was our second project for this client, following a custom label printing system.