Requirements

SMPPL required a comprehensive Data Acquisition System (DAS) to ensure consistent quality of milk delivered to customers. The primary objective was to monitor and log the level and temperature of the milk stored in silos. This data needed to be transmitted to a central software system integrated with the Head Office’s Enterprise Resource Planning (ERP) system via the cloud.

The existing system involved manual logging of level and temperature readings through local gauges. This method resulted in significant gaps in quality inspection, as readings were taken at defined intervals, leaving the quality of milk between these intervals unchecked.

System Solution

FAIZAL implemented a cutting-edge solution for SMPPL, encompassing the following components and functionalities:

1. Continuous Measurement and Logging:
   • Continuous monitoring of milk level and temperature in the silos using advanced sensors.
   • Real-time data logging to ensure no gaps in quality inspection.
2. Edge Computing:
   • Deployment of edge computing devices to process data locally and provide immediate alerts to field operators.
   • Mobile application access to the cloud database for on-the-go monitoring and corrective actions.
3. Cloud Integration:
   • All data from various plants are stored in a secure central cloud hub, ensuring data retention even in case of local server failures.
   • Systematic synchronization between the cloud hub and the central server to maintain local data consistency.
4. Central Software and ERP Integration:
   • The central software, integrated with the ERP system, facilitates dashboard visualization, forecasting, generation of recommendations, issuance of gate passes, assignment of actions to devices, and search functionalities.
   • Comprehensive data analysis and visualization tools for effective decision-making.

System Description

The DAS implemented by FAIZAL for SMPPL includes several key features:

1. Local and Central Monitoring:
   • Data can be monitored both locally at the plant and centrally at the Head Office.
   • Edge computing capabilities allow for pre-emptive actions, reducing operator errors and unexpected equipment faults.
2. Alerts and Notifications:
   • Real-time alerts and notifications for critical parameters such as temperature fluctuations or abnormal milk levels.
   • Mobile application access ensures that operators can respond promptly to alerts.
3. Data Resiliency:
   • Data is stored redundantly in a central access server and a cloud data hub, ensuring high data availability and resiliency.
   • Continuous synchronization between local and central systems to prevent data loss.
4. Forecasting and Recommendations:
   • The central software provides predictive analytics, offering forecasts and recommendations to improve operational efficiency.
   • Detailed reports and dashboards facilitate strategic planning and resource allocation.

Project Outcomes

The implementation of the new Data Acquisition System has yielded significant benefits for SMPPL:

• Reduced Human Effort: Automation of the inspection process has minimized the need for manual data logging, reducing human errors.
• Consistent Quality: Continuous monitoring and control of temperature ensure that the quality of milk remains consistent, meeting SMPPL’s high standards.
• Enhanced Customer Satisfaction: By maintaining consistent product quality, SMPPL ensures that all customers receive the same high-quality milk, reinforcing brand trust and loyalty.
• Operational Efficiency: Real-time data and predictive maintenance capabilities have optimized operational efficiency, reducing unscheduled downtimes and improving overall productivity.

Conclusion

The comprehensive solution provided by FAIZAL has transformed SMPPL’s quality assurance process, leveraging advanced technologies such as edge computing, cloud integration, and real-time data analytics. This has not only enhanced the operational efficiency of Sharif Milk Products but also ensured the delivery of consistent, high-quality dairy products to their customers.