How New Technology Helps You Cope

It wasn't all that long ago when inventory management was just a level sensor with a 4-20 mA output sending a distance measurement to a PLC in the control room. There was lots of wiring and not a lot of data.

Then about a decade or so ago, inventory management software emerged as an alternative to the traditional PLC or HMI. Software programs were installed on local area networks, often managed by IT departments. Graphical interfaces began providing additional data, automated alerts, and offered multiple silo or site management.

In the past few years, technology has exploded. There has been a rapid transition to the Industrial Internet of Things—or IIoT. Sensors increasingly began to use protocols like Modbus and HART. The software went from floppy disc to a virtual cloud as Software as a Service (SaaS). Wireless networks became much more reliable. Tablets and cell phones replaced the desk and chairs in the office.

All of this has revolutionized inventory monitoring whether workers are on-site, working remotely, or are responsible for many sites and silos.

Simplifying the Way Sensors are Programmed

Setting up sensors used to be a cumbersome process that required staff to spend installation on top of a silo or in a control room, painstakingly setting up parameters. Over the last decade, sensors have been conveniently integrated into software programs and web applications.

Some sensors now offer setup using a Bluetooth app downloaded to a cell phone or tablet. Setup can also be completed on a PC using a Bluetooth USB adapter.

Viewing of level measurements and changes to bin parameters can be done via the app at distances up to 80 feet from the sensor. This allows for performing level monitoring and parameter adjustments from the base of the vessel without climbing ladders. Time savings are immediate, and a higher level of safety is assured.

Using an app has many advantages.

• It's Easy: If you can order take-out food on a phone, chances are you can set up sensors without incident
• Simple Download: Get apps from the Google Play Store (Android) or Apple Store (iPhone)
• Real-Time, Secure Data: If changes to vessel parameters need to be made, the information can be quickly updated in the app and made effective immediately
• Safer Workers: Allows for setup and measurements without climbing silos or working in hazardous locations
• Duplicated Sensor Parameters: Reduces the tedious work of having to enter information for each vessel individually, making the process of setting up many vessels faster and reducing the risk of error during setup

Setup is not the only function that can be accomplished using Bluetooth technology. Advanced diagnostics allow for troubleshooting or monitoring maintenance parameters.

Security is assured through IIoT protocols using advanced encryption and user access controls that allow only certain individuals the ability to make changes to settings. Settings can also be transferred to a PC if additional integration into a plant’s PLC systems is desired.

Count on Non-Contact Sensors

A decade ago, the road was bumpy for non-contact technology, especially in dusty conditions typical at many bulk solids processing plants. Early versions of radar-level sensors performed erratically and unreliably in silos with high amounts of dust. They were not powerful enough to transmit through the dense suspended particulate.

Many radars were designed with horns to focus the beam, but the horns would become coated or packed with dust buildup. Manual cleaning or an air purge was often required. This led to a distrust in the level of data being output by these sensors. Remote monitoring was not trustworthy, as the staff was still climbing silos to validate measurements.

The advent of 80 GHz radar technology revolutionized the performance of non-contact radar in silos with excessive dust. A focused narrow beam not only transcends dust, but can be targeted to a very precise location in the silo, avoiding structure and pinpointing the most desirable measurement location. Measurements update in less than a second with an accuracy of ±0.2 inches, allowing the sensor to track the filling and emptying cycles of processing silos.

Data is reliable and real-time, making materials management easier for purchasing personnel. Inventory valuation for financial reporting is accurate, reducing the need for write-offs in future accounting periods.

Monitor Inventory on a Phone, Tablet, or PC

Many large processing plants are big in size and small on staff. Making silo inventory management available anywhere, anytime enables people to be more efficient in their jobs.

Logging into a website using an app or SaaS program puts real-time data in front of people who need it to make timely decisions. Improvements in processing efficiency, ordering, and delivery schedules, eliminating material shortages, and reducing carrying costs are just a few of the benefits of monitoring silo levels while on-site or off-premises. Automated alerts via text or email allow for proactive materials management.

Vendor Engagement in Managing Inventory

Whether working remotely or at the plant, staying on top of inventory is challenging. Silos can run empty. Orders are not placed. There are crucial material shortages. These problems are further complicated by cumbersome spreadsheets, inaccurate inventory reports, and last-minute deliveries.

Many of these challenges can be avoided by allowing vendors to help optimize delivery schedules and ensuring plants have the right amount of material in stock.

Vendor Managed Inventory—VMI—builds a bridge between a plant and its suppliers. It can be accomplished using level sensors on silos that are connected using wireless communications and gateways to a website that tracks inventory in real-time. Vendors are assigned login credentials and viewing rights, so they can monitor inventory in tandem with the plant.

A VMI system is totally automated and keeps inventory levels up to date, 24/7, in real-time. This ensures a plant and its vendors are sharing the same data.

Vendors take on some of the responsibility to monitor the material on hand. They can take a proactive role in scheduling their production to meet demand, placing orders, and scheduling deliveries before work stoppages occur. An added benefit is the validation that an entire shipment will fit into the silos without the risk of overfilling.

The shared software is configured to send automated alerts via text or email at trigger levels before silos run empty. Historical trending shows usage and deliveries and can generate reports to help forecast demand.

Remotely connecting plants and vendors using VMI is a remote strategy that improves supply chain management. It helps increase inventory turns, reduce safety stock, improve cash flow, increase profitability, and cut lead times.

It also can reduce time-consuming meetings, emails, and phone calls.

SaaS on a Website Protects Profitability

No need to feel disconnected from your inventory, even if you're at home and your silos are miles away at the plant.

Using a SaaS, inventory can be accessed using a phone, tablet, or PC via an internet connection. Many software programs are optimized for desktop and mobile viewing.

The most sought-after values of SaaS are convenience and simplicity of use. However, plants see many other benefits.

As inventory management programs are designed to use out-of-the-box, they do not require having an IT specialist on site. All software development is complete, and the program is ready for use. Plus, the software host takes care of all the upgrades and helps train staff. These inventory management platforms are scalable from one silo to hundreds at one or many locations.

Using a website is ideal when centralized monitoring is needed for multiple plant locations. For example, dispatchers need real-time inventory oversight of many plants to properly schedule and route trucks. This improves logistics between plants, optimizes routing, and ensures all locations are running efficiently without material outages.

Dispatchers, drivers, and plant managers can set priorities and reduce out-of-stocks and delivery emergencies, all of which waste time and impact production schedules, and erode profits.

Remote Monitoring: The New Reality

A remote monitoring system starts with sensors. Continuous-level sensors are mounted on each silo using appropriate sensor technology for measuring the type of solid or powdered material.

Non-contact radar, guided wave radar, weight and cable, lasers, ultrasonics, or 3D scanners are some of the sensor types used to measure inventory levels.

When a new measurement is taken, the data from the sensors flows seamlessly to a wireless gateway. There are gateways that accept 4-20 digital inputs, support multiple protocols, and update in two to five seconds.

Next, the gateway instantly sends the measurement data to software in the Cloud. Silo inventory is accessed from a phone, tablet, or PC with an internet connection. Access is as simple as opening a secure website using unique login credentials, then viewing the information on an easy-to-use dashboard.

An intuitive interface is used to set up bin parameters, such as height, diameter, material, and bin location for easy identification. A graphical interface displays inventory levels for each bin. High and low-level alerts can be set to automatically send a text or email when bins are nearly full or empty. The software allows for viewing silos for either a single location or multiple sites. Bins can be sorted by material or alert status.

Wireless Innovations Make a Connected Plant Affordable

In the past, it wasn't uncommon for the cost of electricians, installation, and wiring to more than double the cost of an inventory management system. In the past, expensive wiring prevented plants from becoming connected plants, causing personnel to be disconnected from their inventory. Running long spans of wire outdoors was unfeasible and impractical.

Wireless devices are the missing link between sensors and the software that connects workers with data to do their jobs better. Wireless gateways, transceivers, modems, and repeaters have greatly reduced the wiring complexity, requirements, and expense of installation. Long range – or LoRa – antennas allow transmission of data up to a mile line of sight. This eliminates the need for running long spans of wire, making installation far easier even for the largest plants.

A gateway is used to flow data seamlessly from the sensors without extensive wiring for on-site and remote monitoring of silo inventory.

Gateways combine the functions of a wireless access point, modem, and router in one convenient device. They utilize ethernet, Wi-Fi or cellular connectivity to get data to a PLC, software, or web application. Wiring level sensors together in a daisy chain wiring schematic require only a single gateway to send data seamlessly from the sensors to the software.

Wireless bridges and gateways are very reliable in getting data from point A to point B. They are robust and durable in outdoor environments. At the same time, the price of these devices has lowered significantly—finally making a connected plant affordable.

Technology applied to level sensors and inventory management software applications is changing rapidly and for the better. A system can quickly provide a return on investment in process improvements that lead to less downtime and greater productivity without adding headcount to existing staff.

It is an ideal time to integrate a new sensor solution into your operations plan. 

Start finding your solution at BinMaster.com!