In the animal feed production sector, efficiency and precision are essential to guarantee the quality of the end product and meet customer requirements. Artificial Intelligence (AI) technologies are playing an increasingly important role in optimizing production processes.
This article explores some solutions that use AI to solve a common problem in the manufacturing industry: the lack of real-time connection between PLCs and ERP software, which generates long delays in receiving data from the PLCs.
Problem: Lack of Connection Between PLCs and ERP Software
In a feed production plant, PLCs play a crucial role in managing various aspects of production, such as ingredient dosing, mixing and quality control. However, without an effective connection to ERP (Enterprise Resource Planning) software, the data generated by these PLCs cannot be integrated into the central management system in real time.
Consequences
- Extended lead times: The absence of a real-time connection leads to delays in receiving crucial data from the PLCs. This affects the ability to take and confirm raw material orders quickly.
- Inefficiency: Production processes are slowed down because decisions based on PLC data cannot be made instantly.
- Human error: Manual data transfer increases the risk of errors, which can affect the quality of the final product.
Solution: Establish a Real-Time Connection Between PLCs and ERP Software
Customized Solutions Using AI
The integration of AI technologies offers an effective solution for establishing a real-time connection between PLCs and ERP software. For example, with a customized FileMaker application, our web application developers can help manufacturers manage the entire life cycle of their products, from raw materials management to delivery of the finished product.
Customized Filemaker solutions automate the flow of data between PLCs and ERP software, eliminating the need for manual transfers. Data can be processed in real time, ensuring that crucial inventory and production information is immediately available to managers.
In addition, the application can analyze historical and current data to forecast raw material requirements and optimize stock levels, thus reducing lead times and costs.
Implementing AI Solutions
Assessing Existing Systems: The first step is to evaluate existing PLC systems and ERP software to identify possible connection points.
Customized Application Development: An Application is developed to enable communication between PLCs and ERP software.
AI Integration: AI algorithms are integrated to process real-time data and provide predictive analysis.
Testing and Optimization: The integrated system is tested and optimized to ensure maximum performance.
For example, a barcode system can be linked to the global management system. In this way, all products handled by the manufacturer’s teams can be equipped with a barcode, whether raw materials or finished products. With the barcode system, manufacturers can check results in real time. This is very useful, among other things, for product batch traceability, optimal warehouse management and product shipment processes.
In this way, the entire management of raw materials required to manufacture products can be carried out by the system, from raw material reception to inventory and location management, taking account of expiration dates and stock utilization.
Benefits
Real-time connectivity enables fast, efficient decision-making, reducing lead times for receiving and processing raw material orders. Production processes are optimized thanks to the automation and data accuracy provided by customized applications. In addition, human errors are minimized, guaranteeing better product quality and conformity.
Conclusion
AI technologies offer innovative solutions for improving efficiency and precision in animal feed production. By creating a real-time connection between PLCs and ERP software, manufacturers can overcome the challenges of data delays and process inefficiencies. This leads to better inventory management, reduced costs, and an overall improvement in product quality, ensuring customer satisfaction and competitiveness in the marketplace.
At Direct Impact Solutions, we are committed to integrating advanced technological solutions to meet the specific needs of our customers in the manufacturing sector. Our expertise in AI and automation enables us to deliver services that exceed expectations and ensure exceptional performance at every stage of the production process.