Full cycle automation: from technological equipment to ERP systems

The Viking-Yug grain storage automation project is a great example of how innovative tech solutions and a forward-thinking customer can create a really efficient and reliable system. Instead of piecemeal improvements, Viking approached us with a clear, well-thought-out list of requirements based on a comprehensive understanding of its own business processes.

This approach, which was the exception five years ago, is now becoming the norm for successful enterprises.

Початкові умови та запропоновані рішення

A partially operational automation and SCADA system was already in place at the enterprise when Viking-Yug approached us. The work had been carried out by another contractor, but before launching the elevator, the customer encountered a number of critical issues that they were unable to resolve on their own:

• Limited functionality of the current SCADA, which did not meet all the needs of the elevator.
• The need to implement several industrial automation products (process control system, automatic weighing complex, thermometry, etc.) and integrate them with business automation products.

"The project with Viking was interesting and very useful, because it was a truly conscious request to implement a comprehensive vision of business process automation. If a business has matured to the point of understanding its own needs, there is a system in place for the requirements — technical implementation is much faster, cheaper, and of higher quality for both parties. We offered a solution based on the philosophy of a single manufacturer," notes Sergey Artyushkin, Head of R&D at Grain Capital.

The main requirements for the new SCADA system were:

• Web server architecture: provides remote access to the system from anywhere via a browser.
• Individual accounts: for monitoring staff actions, analyzing efficiency and accountability.
• User-oriented visualization: as close as possible to the real topology, intuitive for quick mastering.

There was also a desire to have as many products as possible from a single manufacturer:

• a single support and service center;
• logic and design built using the same methods, which significantly reduces training time;
• ease of mutual integration;
• as a result, the total cost of ownership is much lower than investing in a “supermarket” of products from different brands.

We can safely say that all this and even more has been brought to life. In addition to replacing SCADA with smart.sdau, the comprehensive automation system includes smart.thermometry and smart.scales products.

Overall, this project can be considered a good example of a modern approach to providing technical solutions that meet business requirements. 

About integrated Smart Products

Our smart.thermometry and smart.scales products have become an important component. They combine maximum reliability of industrial automation with the advantages of modern IT solutions.

• Integration: The integration capabilities of Grain Capital's modern solutions allow you to combine separate areas and zones of responsibility into a single, transparent, and controllable system.
• Shipping automation: The entire shipping process (including operational communications, accounting, document flow, and actual execution) has been solved by combining the accounting system and smart.scales via API. Data from the accounting system becomes a ready-made task for smart.weighing scales, and actual indicators are automatically transmitted back. This eliminates the human factor, misunderstandings, and unauthorized shipments. A significant advantage of automating processes related to grain quality and quantity is the avoidance of misunderstandings and conflicts with depositors and logistics companies. 
• High-precision and secure weighing complexes: Two certified Grain Capital weighing systems based on Siwarex electronic weighing modules manufactured by Siemens provide an accuracy class of 0.2. The control system and software control over all control actions guarantee protection against manipulation – both at the physical level with equipment and with actual performance indicators.

Each set of scales has an independent technological branch, which allows Viking to simultaneously ship two crops or two classes of one crop by road.

 Additional feature for weighing equipment software:

The project with Viking was beneficial for both parties. Products are being developed in a high-quality manner, meeting clear business goals and needs. At the request of our partners, we developed an additional feature: a safeguard against vehicle overload.

This feature allows you to set a percentage of the task weight, upon reaching which the task is automatically suspended. The operator has the opportunity and time to visually assess the situation (for example, through a video surveillance system) and decide whether to continue shipping. This is critically important during the “season” when logistical errors occur more frequently, and helps to avoid overloads caused, for example, by the arrival of smaller trucks than planned.

In conclusion, let us note that modern software, a reliable and well-informed team, considered risks, and specific diagnostic data — is an investment, the cost of which is significantly lower than the expenses of accidents, seasonal downtime, and reputational losses.

This project is a good example of a modern approach to meeting business requirements with technical solutions.