Comprehensive Automation of Operational Accounting for Starch, Fructose and Syrup Production
From truck weighing to end-to-end production traceability
The project involves the phased development of a unified operational accounting and control system for a large enterprise producing starch, fructose and syrups.
Automation started with one of the core operational areas — vehicle movement and raw material accounting at the truck weighbridge. The system was then gradually expanded to cover new production, laboratory, warehouse and logistics processes across the enterprise.
Raw material receiving and transport logistics
The system automates the accounting of incoming vehicles, raw materials and weighing results. Weighbridge data becomes part of a unified information chain and is used at the subsequent stages of receiving, laboratory control, unloading and production accounting.
The system links the vehicle, delivery, weighing results, sample collection and the subsequent movement of raw materials across the plant.
Laboratory and sample collection
A separate automation module covers sample collection and identification, transfer of information to the laboratory, registration of test results and their association with the specific batch of incoming raw material.
This makes it possible to include laboratory control data directly in the operational traceability system and use it when making decisions about the further movement and processing of raw materials.
Unloading and raw material allocation
The operator workplace for raw material unloading has been automated. The system helps control where incoming raw materials are unloaded and into which storage bins they are allocated, taking into account laboratory test results and production requirements.
Transfer of raw materials to production
The next operational module covers the transfer of raw materials from storage and accumulation areas to preparation and further into the production process. A continuous history of each batch is created from the moment a vehicle enters the plant through to the actual use of the raw material in production.
Production areas
As the project develops, automation is gradually extended to individual production areas. Specialized automated workplaces are created to register production operations and track the movement of raw materials, semi-finished products and finished goods.
The core principle of the project is the gradual connection of new operational modules to the already functioning system without the need to redesign all existing enterprise processes at once.
Packaging and weighing of finished products
At finished product output areas, packaging, weighing, identification and registration operations have been automated. Information about each batch is linked to production data and is subsequently used in warehouse accounting and shipment operations.
Finished goods and auxiliary materials warehouses
The system also includes warehouse accounting for finished products, packaging materials and auxiliary materials. Receiving, put-away, internal movements, picking and issuing of inventory items are automated.
Internal supply warehouse based on the “supermarket” principle
A separate operating model has been implemented for the internal supply warehouse based on the principle of an internal “supermarket”. Employees can directly select the materials they need in the warehouse and register their receipt using a mobile data collection terminal, without creating a separate preliminary order.
This approach simplifies the issuing of frequently used maintenance and operating materials while preserving personalized operational accounting of their movement.
Integration with video surveillance
The operational accounting system is integrated with the video surveillance system. Video data is used not only as a security tool, but also as an additional source for monitoring production and accounting operations.
This makes it possible to associate events in the accounting system with the relevant operations at the weighbridge, unloading areas, warehouses and other controlled points.
Integration with corporate systems
The operational system is integrated with the enterprise accounting system and the maintenance and repair management system. The operational layer handles the direct registration of real production events, while the corporate systems receive the consolidated information required for further accounting and management.
Digital traceability and web passports
The further development of the system includes the creation of a digital product history and the use of web passports. These make it possible to combine information about the origin of raw materials, production operations, laboratory control, finished product batches and subsequent shipment.
As a result, end-to-end traceability is created — from the receipt of raw materials at the enterprise through to the production and shipment of finished goods.
Project approach
A key feature of the project is the gradual development of the system. Automation was not designed as one large-scale project that had to be launched simultaneously across the entire enterprise. Work started with individual priority areas, after which the system was progressively expanded to include additional production modules.
This approach makes it possible to verify solutions directly in operation, take into account the real specifics of production and gradually build a unified system for operational accounting, control and traceability across the enterprise.
