Fast-paced work environments are driving the need for accurate, real-time data. Sensor manufacturers and software developers have been working rigorously to create new and innovative solutions.
Is your operation seeking ways to more efficiently monitor inventory? Check out these popular trends.
Sensors that Work in Dust
It wasn't that many years ago that the roof of silos were a graveyard of level sensors. Plant managers were anxious to be more efficient and proactive when managing inventory. Many tried new products, but to no avail. The most common sensor complaints were inaccurate readings, a short service life, and far too much required maintenance. Operations were frustrated by trust issues.
Their frustrations did not fall on deaf ears. Sensor manufacturers looked to modern technologies and product improvements that could overcome typical challenges in powder and solid storage silos. These sensors had to work continuously in potentially dusty environments and sticky materials. While traditional weight-and-cable-based sensors would work reliably, plants sought a non-contact sensor that would measure continuously.
Two technologies emerged over the last decade that could finally meet these demands: an acoustics-based sensor that used sound waves to measure multiple points on the material surface in the silo, and 80 GHz non-contact radars that could overcome the shortcomings of its predecessors.
Doing Away with Expensive Wiring
Running long spans of wire outdoors is often unfeasible and impractical. The cost of installing hundreds—if not thousands—of feet of wire, plus several poles to support wiring, could not be easily justified. In many cases, wiring has prevented worksites from becoming “connected plants,” keeping personnel from access to their inventory.
Wireless devices were the missing link between sensors and the software that provided workers with the data to do their jobs better. The advent and proliferation of wireless technology changed the landscape at industrial plants.
Wireless bridges and gateways have become dependable in getting data from point A to point B. They reduce installation costs by eliminating hard wiring. Devices continue to be reinvented for robustness in outdoor environments and harsh weather conditions. The price of these devices has also come down significantly, making a connected plant more affordable.
Accessing Inventory on a Phone
If there's one thing that almost every employee at any plant has in common, it’s a cell phone—the device relied on for almost everything personal and professional. Today, 86% of adults in Canada are reported to have a cell phone. On top of that, 91% of Canadians are reported to use the internet. Those who do expect it to make their life easier.
Inventory software apps are becoming increasingly user-friendly as they are optimized for mobile devices. Any phone that has internet access can become a powerful business management tool. Personnel are able to access their silo inventory data from their phone, whether they are at the plant or offsite.
Software as a Service (SaaS) subscriptions now proliferate in most industrial businesses. They are used for everything from Enterprise Resource Planning (ERP) to human resource management to a company’s website. At industrial plants, cloud software is used to manage inventory and optimize purchasing.
Displaying Data Locally
The mining, cement, and agriculture industries have plants that cover several acres of terrain, sometimes with multiple locations that are located miles from one another. Even in more industrialized environments—like food processing, plastics, and chemical plants—silos are often spread out across the plant or clustered in remote groups. Plant personnel needs to know how much material is in each silo, which silos have remaining capacity, and which to pull from next.
Accessing silo levels in real-time saves time—and employees. Falls are among the most common hazards in the workplace; they can now be avoided using a small, simple device. Eliminating climbing silos to check levels makes CCOHS compliance easier.
Digital panel meters have come a long way in design and affordability. LED technology makes them easy to read, even in bright sunlight and dust. Plants install digital panel meters to make level data available for every silo. They are used at loadouts by drivers and by personnel managing scheduling and production alike.
Simplifying Sensor Replacement
A common theme among manufacturers is a shortage of qualified staff to get maintenance work done. With unemployment in Canada hovering around 5.5% [July 2022], it's difficult to recruit full-time staff. Manufacturers have begun outsourcing work to third-party vendors and licensed electricians to keep operations running smoothly.
Industrial plants—many of which are characterized by dusty, dirty, or harsh environments—are tough on level sensors. Equipment must be maintained on a regular basis and occasionally replaced altogether. When plants lack staff and but must follow a rigorous preventive maintenance schedule, they require a solution to make tasks go quickly with less qualified staff.
Adding a Quick Disconnect—or QD for short—has become a time saver for plants facing these challenges. These inexpensive accessories take the tedious task of hard-wiring sensors and turn them into a plug-in operation. No licensed electrician needed! Staff can spend less time installing, replacing, or maintaining a sensor. QD connectors can be purchased separately for retrofit, or some manufacturers will ship new sensors with the QD option already installed.
Have inventory problems you need to solve? Reach out to the experts at BinMaster. YOU are the future of inventory monitoring!
