Saha Asia Data Collection System R1

smart-DIGITALIZATION
SAHA ASIA INDUSTRIES
Let’s Create Value Together
Golden Bull
Award Winner
IIOT-AUTOMATION ECOSYSTEM PARTNER 2020 @ EA MAX SOLUTIONS SDN BHD. CONFIDENTIAL. ALL RIGHTS RESERVED.
PROJECT OBJECTIVE :
- Supply control system to give semi-automatic production line
and data logging for each process.
- Collect required data and give user more organised in machine

control & higher visibility on machines OEE & MU.
- Transfer local data to system cloud basis will enable the users to
log in the system anywhere and anytime to check their
production line.
- V-One Technologies is used to organize all the data from cloud

and transfer it via visualization by charts, statistic and current
production view.
- Inventory Management System (IMS) enable user to facilitate

management in their daily planning in the performance of
material movement and storage in and around a warehouse.
IoT 4.0
- Helps to manage and optimize all aspects
of your manufacturing processes and supply
chain. It gives you access to the real-time
data and insights you need to make smarter,
faster decisions about your business, which
can ultimately boost the efficiency and
profitability of your entire operation.
- Gather real-time data from all parts of the

manufacturing process so decisions can be
made quickly and efficiently
V-ONE
- Centralized Vision Inspection Command Center
- Equipment Utilization & Optimization
- Machine Monitoring & Predictive Maintenance
- MES Integration & Process Traceability
- Factory Energy Management System
- Factory Environment Monitoring
- ERP Integration & KPI linkages
SAHA ASIA
Shop Floor Digitalization
Problem Statement
NO EXISTING DIFFICULTY SOLUTIONS IDEA IMPACT
1 Manual operation to - Adding PLC will help to semi-automated some of the - Improvise some of the equipment to ease the users to monitor the process line.
start/stop system and lack production line. - Time-stamp will be provide for each process in the production line.
equipment to track the - Sensors and other instrument will communicate each other
production and employee in the process to give monitor the data time to times.
performance.
3 No data logging has - Flow meter sensor will help more with this process. - All the data flow will be more cleared to view by top management and the
recorded start from raw - The system will help the users to capture and store all the interesting part is the data capture live from site.
material until product finish. data into cloud. - Ease to track and to prevent from wrong data given.
4 The filter from filteration - Install pressure transmitter for each before and after filter. - This function will give more benefits to user in-term of:
process will clog after many i. Cost – pipe burst.
times used. ii. Production – the flow before and after filter will be purer.
iii. Accurate data - let users to change/clean the filter when the times come.
5 Avoid storage tank from - Installed Oil level sensor to get accurate data fore each - Automate the transfer pump to stop after the oil level achieve to certain point
overflow. tank. and will allow the operator to change to new tank or stop the process.
6 Heat loss between heater - Temperature controller is the best solutions to maintain the - Avoid the heat loss between the tank.
tank to mixer tank. temperature. - Can support the user to keep monitor the temperature from time to times.
- Installing temperature sensor at both tanks,
Shop floor
TANK 3
HEATER MIXER C
TANK TANK O
N
M2
V
TANK 1 E
Y
TANK 2
O
M3 JERRY CAN R
M4 PET BOTTLE
M1
REMOTE TERMINAL STATION (RTS)
10 INCH PANEL PC / IND HMI
For Manual Data Entry :

1. QC reject classification
* To be install on the machine or next to the machine 2. Machine downtime classification
(option)
PROPOSE
PANEL 1
- To collect all the digital input and analog input data in
TANK 3 the system and control some of the equipment as
request by customer
PANEL 2
- Will be located as centralize for Digitalization Area to
collect all digital input data.
HEATER MIXER C
TANK TANK O RTS
N
M2
V - Will be the head of controlling area and collect data from
TANK 1 E panel 1 and panel
Y
TANK 2
O - The panel for key in reject quantity, planned/unplanned
Panel 1
M3 JERRY CAN R
downtime, and control production line.
Panel
2
M4 PET BOTTLE
M1
RTS
Control Line 1
Concept Proposal
Concept
Process will be transferring the oil from semi truck
tank to storage tank by individual selection manual
valve.
Propose.
- Oil level sensor for each tank to provide
accurate level for each tank and to cut-off
the transfer pump 1 if any selective manual
valve already select.
- This concept will be repeated for each tank
or will stop the sequence by PIC of the day.
- Proximity Sensor will put at Each valve to
get signal fully open and fully close signal.
Concept
Each oil tank have individual output valve to go to process in
the mixer tank. By using transfer pump 2, the pump will run to
transfer from oil tank to the mixer tank. After done mix the oil,
the output valve at the mixer will open and deliver back to the
same storage tank.
Propose
- Add pressure transmitter at before filter and after filter
for differential pressure.
- Flowmeter before mixer tank to record the amount of
oil to be from storage tank to mixer tank.
- Temp. Controller at the heater tank used for keep
the same heat at mixer tank and heater tank.
Transfer Pump 3
- Vertical float switch using for stop the transfer pump 2
when oil already full in the mixer tank.
- Timer will be set and after mixer finish process.
Transfer Pump 3 will run and transfer back to the same
oil Tank.
- All the Valve will select in manual way.
Control Line 2
Concept
After done mixer process, the oil will keep in the oil
tank before use to transfer to 2 other production line
for packaging, capping and labeling. The 2 line in
production line is called by Filling Machine Jerry Can
and Filling Machine Pet Bottle.
Propose
- Add pressure transmitter at before filter and
after filter for differential pressure data.
- Flow meter is installed after the filter to
monitor the flow out to each filling bottle.
NO Type of Sensor Place Function
1 Temperature Sensors - Mixer Tank Keep the temperature data and monitor the heat at heater tank and mixer
- Heater Tank tank
2 Oil Level Sensor - Storage Tank 1 Give acknowledgement of level of oil inside the storage tank
- Storage Tank 2
- Storage Tank 3
3 Pressure Sensor - Filter 1 Give differential pressure between the filter to helps user acknowledge
(Located before mixer tank) between the sensor
- Filter 2
(Located at Jerry Can)
- Filter 3
(Located at Pet Bottle)
4 Vertical Float Switch - Mixer Tank Give a contact signal act as mixer tank level before start the mixer tank
Sensor (Oil)
5 Flowmeter Sensor - Transfer Pump 1 To keep track all the oil flow from storage tank until transfer to the bottle.
- Mixer Tank
- Jerry Can Prod. Line
- Pet Bottle Prod. Line
6 Proximity Sensor - Each valve at transfer from Semi- Allow the system know when the valve is fully open and fully closed.
Truck to Storage Tank
7 Color Sensor - After conveyer from Jerry Can and Function as counter to the end of product to clarify the full quantity that
Pet Bottle produce.
Digitalization Area
Product
System architecture
Sensor
Panel 1
Analog Input
Cabling
Machine
Digital Input
Cabling CC-Link
Labeling
Ethernet
Filling CC-Link
RTS
Panel 2
Capping
Sealing
IMS – Inventory Management System

1 Current system are with basic material movement transactions
2 Current movement transactions are not real time
3 Existing process requires manual operation
4 Existing processes are human dependent
5 Limited traceability in current system
What is RFID | How does it work?
Radio FrequencyIdentification is the new generation of wirelesstracking technology that utilizesthe radio wave
transmissionin communicatingbetweenthe reader/interrogatorand tags/transponder.
Thegeneral advantagesof RFIDare:

 Unique & fast object identification
 Long read range
 Multiple tags simultaneous reading
 Non line-of-sight reading
 Rewritable tag information
RFID Trolley RFID Printer RFID Tunnel RFID Gate
ERP / Application Software
ANTZ CORE
RFID Forklift RFID B/T Dongle RFID Mobile Terminal RFID Gantry
Proposed Solution
IMS system is hosted on

cloud server which enable
SaaS modal
User/stakeholders get
information/notification from IMS
Mobile computer scan Desktop printer and mobile (direct from portal or via email)
Barcode/QR code, perform printer get printing
transaction and upload to information from cloud
cloud server byreal time server
Print &
Barcode/Q
R code label
Solution Overview
Barcode/QR code Label
RK 25 Barcode Mobile Scanner Barcode Printer
ANTZ Inventory Management System
Cloud Server On-premise server
Implementation
Methodology
Barcode/QR code Label Printing
Barcode
Printer
• Barcode Printer enable user to print labels with ease.
• System will register the item and add into inventory list.
• Once label is being printed, it shall be tag to the individual item
respectively.
• Item shall be digitalize once tagging is done.
Barcode Tag & Tagging Methodology

Standard Barcode Label
• Low cost
• PET material; weatherproof which is able to withstand
water and sunlight
• It can be printed with standard barcode printer
(example: GT800)
Barcode Tag & Tagging Methodology

Standard Barcode Label
(sample)
Pallet # : 33
Front Supplier : SAHA ASIA
Batch : 12/10/2021
P/N : 12345678900
Pallet # : 33
Supplier : SAHA ASIA
Batch
: 12/10/2021
P/N
: 12345678900
• Item description, P/N, Batch (Lot), QR code printed

on-demand with barcode label printer.
• Miss scan might occur if Barcode/QR scanner
Tagging of label to be done on each pallet,
didn’t align with the barcode/QR code
which allows us to digitize asset and
gaining visibility whenever it is being
scanned by a Barcode scanner
Barcode Scanner
Barcode
Scanners
• Barcode scanner shall be used to update status /
location of items.
• “Dispose”, “Consume”, “Outbound / Status Update”
function enabled at ANTZ IMS software module.
• Read range of 2 – 3m is achievable.
SYSTEM SETUP
ANTZ IOT Platform
Barcode Barcode Mobile

Printer Scanner ERP / Local host
Cloud Server & Network Infrastructures
Execution Devices Back End System
Barcode Printer
Barcode Platform
Restful Web API layer
Restful Web API layer

Back End Integration
Device Integration
SQL Database
ERP Gateway
Mobile Scanner
ERP
Serialization Module Components
Core Logic / Shared Library
Hardware Management
Business Logic Layer
Hardware Setup – Network

PC Dekstop / Laptop
[LAN / WIFI] Barcode Printer
[LAN]
WIFI AP
Network switch
Barcode Scanner
[WiFi/GSM]
Server for Application Hosting

Project Timeline
Design & Installation & Handover & Go-live

Requirement Development commissioning & support
Detail operational & Site installation &

functional requirement configuration
study Hardware ordering
User Training
Architectural and Software system
Documents Submission installation, SIT, UAT
& Approval application design
On-site testing &
Hardware installation & support
Integration requirement System development &
programming tuning
discussion
12 week Database Management 2 week

2 week
3 week
THANK YOU
Technical On site / Virtual Implementation Application

Support Training Support Knowledge
Centre
Let’
s talk
Feel free to contact our friendly Send your inquires to Need Help ? We are here!
Customer Care Executives sales.eamax-automation.com Let’s Chat!
Office : +603-8062 8030 and we will get back to you soon. Whatsapp : +6013-8030 633 .
Mobile : +6013-8030 633
EA Max Solutions Sdn. Bhd. [900886-W]

No. 32-2B, Block, Jalan Tasik Prima 5/2, Prima Biz Hub, 47150 Puchong, Selangor D.E. Malaysia. Tel : +603-8062 8030 Fax : +603-8062 7980 Email : sales@eamax-automation.com
www.eamax-automation.com

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smart-DIGITALIZATION

SAHA ASIA INDUSTRIES

Let’s Create Value Together

- Collect required data and give user more organised in machine

- V-One Technologies is used to organize all the data from cloud

- Inventory Management System (IMS) enable user to facilitate

- Gather real-time data from all parts of the

REMOTE TERMINAL STATION (RTS)

10 INCH PANEL PC / IND HMI

For Manual Data Entry :

NO Type of Sensor Place Function

IMS – Inventory Management System

2 Current movement transactions are not real time

3 Existing process requires manual operation

4 Existing processes are human dependent

5 Limited traceability in current system

What is RFID | How does it work?

Thegeneral advantagesof RFIDare:

RFID Trolley RFID Printer RFID Tunnel RFID Gate

ERP / Application Software

IMS system is hosted on

Barcode/QR code Label

RK 25 Barcode Mobile Scanner Barcode Printer

ANTZ Inventory Management System

Cloud Server On-premise server

Barcode/QR code Label Printing

Barcode Tag & Tagging Methodology

Barcode Tag & Tagging Methodology

• Item description, P/N, Batch (Lot), QR code printed

ANTZ IOT Platform

Barcode Barcode Mobile

Cloud Server & Network Infrastructures

Execution Devices Back End System

Restful Web API layer

Restful Web API layer

Core Logic / Shared Library

Business Logic Layer

Hardware Setup – Network

Server for Application Hosting

Design & Installation & Handover & Go-live

Detail operational & Site installation &

12 week Database Management 2 week

Technical On site / Virtual Implementation Application

EA Max Solutions Sdn. Bhd. [900886-W]

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