Collect, Connect, Control
Call us! +1.919.732.7872 x723

Overview

If something fails and no one there is to detect it and report the failure, did it really fail? With so much safety, compliance, and critical equipment in place, you would think that wireless distributed remote monitoring equipment would already be in place in almost every aspect of our lives. Surprisingly a very small percentage of the things we take for granted to keep our lives moving and keep us safe is actually monitored by more than someone driving by every once in a while to check on the status of the equipment to make sure it hasn’t failed. Only at the time that a concerned citizen or a conscripted agent reports the failure did the failure actually occur – if it is seen and reported the failure actually exists!

cellio_day_night1

 

What is the Equipment Doing When We Aren’t Looking?

With most of the equipment deployed today; nothing is checking on status – good or bad. The assumption for most equipment is that unless someone complains about it, it must be fine and functioning properly. Of course many of us have experienced that eerie intersection where all the lights are dark or even worse they are all blinking yellow (and at the very worst they are all green). These situations can exist long enough for there to be real damage to people and property. If, as we would propose with Cellio, those lights were monitored wirelessly and remotely, the moment that a light failed, the failure could be immediately detected and transmitted to notify everyone and anyone who needed to know about the failure to address the issues until the failure was resolved. For the traffic light example, the police could be notified immediately to get to the intersection to help direct traffic, the power company or the municipality could dispatch someone with the correct parts to replace the failed item. In Open Data Initiative (ODI) communities, that information could be shared via maps and road condition systems to alert people to the condition before they found themselves in real danger.   Cellio is always watching the equipment (24/365) with the sole purpose of detecting the failure and reporting it to back-end data systems where the information can be used to quickly address the issue. Cellio can also take measurements across continuous levels and control electronic devices remotely. 

 cellio_day_night2

 

Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available and in place today. There is a saying that you should “Inspect what you expect”.  If the expectation is that critical equipment used for safety, critical processes, or reliable information on the status of assets, then Cellio should be the first system you evaluate. Cellio will keep an eye on things for you, day and night.

cellio_day_night3

Overview

The convergence of technologies and trends can result in indelible changes that ripple throughout an industry. As noted in a recent NPR piece, “What Is A Paradigm Shift, Anyway?”, paradigm shifts are denoted by replacing the usual way of thinking with a different way. One example trend is replacing manual field data gathering with distributed automated devices that consistently, regularly, and accurately collect and transmit data from sensors to the back-end where it can be aggregated, analyzed, displayed, and automated. Cellio is the technology platform upon which these subtle systemic shifts can occur as business owners, business pressures, or changes in process and supply chain demand them.

cellio_paradigm1

 

Select Systemic Shifts

There may be a number of shifts going on in parallel when an organization has a platform like Cellio. These shifts taken independently or in combination may lead to a new standard that all competitors will have to follow just to keep from losing their position. These source of these shifts can be based on many different elements:

  • Low Total Cost of Ownership (TCO) that is not only low cost, but even less expensive than the traditional equipment installed
  • Very low equipment/CAPEX costs allowing for more flexibility in cash flow and cash reserves
  • Rapid and relatively low installation effort
  • Consistent and dependable reporting of data from the field
  • Remote control from the same dashboard to the same devices
  • Fully integrated end-to-end (E2E) offering out of the box
  • Full system deployments possible in the span of hours or days

 cellio_paradigm2

 

Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available and in place today. There is a saying that you should “Inspect what you expect”.  Looking at a paradigm shift, before it has shifted, is a bit like betting on the lead candidate, who happens to be the underdog, before the race has completely been run. The best bet is to get behind that candidate and help make sure they get across the finish line first.

cellio_paradigm3

 

Overview

“So now I can see the level of feed left in the bins around the farm, what’s the big deal?” The answer would likely depend on the size of the farm, if the farm is part of a network of farms, how fast the bins could be replenished, the rate at which the feed was being consumed, and the value assigned to the animals being fed by the bins around the farm (just to name a few factors). But, from a technology perspective, having all of that work from end-to-end reliably every day, is a REALLY BIG DEAL! The stories of enterprise-wide industrial implementations that are both affordable, scalable, and successful are few and far between. Usually the individual elements are not the confounding factors – it’s the connections between them. Cellio has built a recipe that guarantees success every time!

cellio_success1

 

Begin at the Very Beginning

In the ecosystem that is an IIoT implemented end-to-end system, the most important part is good data being collected in the field. There are many choices of sensors that can be used to collect data – typically the more accurate and more industrially designed devices are the more expensive choices. Thus, it is important to strike a balance between what is a “must have” versus a “nice to have”. For example, a sensor that could provide a level measurement down to the millimeter might be nice (and likely in the $1,000’s), while knowing every foot or two of the level is what is actually useful and actionable (and likely in the $100’s). In combination with the sensor selection, whether the sensor requires a powerline to be pulled to it or not will also impact the cost and should be included the Total Cost of Ownership (TCO) calculation.   The data needs to be collected from the sensors by a device (Transceiver) that can then transmit that data a great distance (say up to a mile) to a central location (Gateway) where it can be packaged up before sending to the internet (some say cloud). Cellio has this built in.

cellio_success2

 

From Earth to Cloud (Internet)

Once the data from the sensors is collected, it is then ready to be sent to through the network to the “cloud” (another name for the internet) where it can be stored with the data from all the other sensors.   In the case of Cellio, the devices that collect the data from the remote sensors is called a Gateway. The Gateway can communicate over cellular (CDMA/Verizon and GSM) as well as over Wi-Fi (which could connect to a landline, ADSL, Cable, Satellite, etc.).   From there, whether over a VPN or the public networks, the data can be sent to a cloud storage location. Making all these connections, transitions from real world levels to electronic signals to local wireless transmissions and ultimately cellular transmissions to the cloud storage can take quite a bit of planning if done from scratch.   Cellio has this built in.

cellio_success3

 

And Now for the Show

As the data is collected in the back-end (cloud storage) it can be used for many purposes:

  • Displayed as part of a dashboard (including mobile workers)
  • Shared with other corporate/enterprise systems (quality and optimization)
  • Shared with partner organizations (supply chain)
  • Analyzed for specific trends and triggers (alerts for managers/workers)
  • Automate inter-related processes (ie re-ordering)
  • Archived for future use (deep trends and forecasting)
  • To control other parts/steps of processes and equipment (automation)
  • And many more…

The initial value for many owners is the immediate gratification of seeing the data they used to have to collect manually (or hope was collected manually in a timely manner) in a consistent, accurate, reliable format. Having this data reported in a timely consistent manner helps them with better visibility of their operations, inventories, and status of equipment that is critical to running their business. For organizations that are beginning a modernization phase, this is a relatively quick, low cost, low risk step into the earliest stages of automation. For the most sophisticated organizations, this can be the way to get in all the “extra” data that has been needed to validate current analytics that have some “blindspots” due to a lack of granularity of the geospatial data available. Cellio has this built in.

 cellio_success4

 

Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available in place today. There is a saying that you should “Inspect what you expect”.  With Cellio, you have recipe you need for a full end-to-end successful IIoT deployment. You can count on Cellio. That’s the big deal!

cellio_success_5

 

Overview

Over the years, we have heard many different pronunciations for our product “Cellio”.  We tip our hats to the global influences that produce such a wide variety of impressions of the product. It may help to have some historical context about the product, the design philosophy, and some counter examples of saying Cellio.

cellio_pronounce1

Cellular, Cell, Cellio

The easiest way to remember the preferred pronunciation is to keep in mind that the first part of the name comes from the word “Cellular”. Thus “Cell” is pronounced the way you would expect it to be pronounced – phonetically /sel/. The founders, engineers, and history of Device Solutions is steeped in a heritage of decades of designing cellular phones and RF devices (from the original analog bag phones to modern day smart phones, Wi-Fi, Bluetooth, 900MHz and many many more). Thus, a cellular based name was the natural first choice – choosing Verizon to be the first network partner with CDMA technology and Telit as the module vendor.

 

There is an “i” in Input (it’s also great for Innovation and Imagination)

Cellio most important initial virtue for customer is the “input” nature of data collection, reporting, and monitoring. Cellio supports both analog and digital inputs (including bus structures for communicating with more advanced sensors and controllers). The broad range of applications; retrofit, new installation, and innovative solutions leveraging the “input” capability of Cellio has been beyond our original imaginings. In the Cellio name the “i” is pronounced as a long “e” or phonetically as /ē/.

 

Add an “o” to Complete the Loop

The complete value for many customers is being able to complete the loop from input, to data stored/displayed/analyzed, to automated (and semi-automated) actions that require data to be sent back to connected alerts, buzzers, switches, and controllers. This is the “output” aspect of Cellio “o” – phonetically /ō/ – which provides the resources to be able to support remote control.

 

Cellio – An IIoT Rose by any other name…

Putting it all together, we pronounce Cellio phonetically as /selēō/. The variants we have heard over the years include, but not exhaustive:

/CHelō/ – The musical stringed instrument “cello”

/CHelēō/ – The musical stringed instrument “cello” with an “ē” inserted

/selŸīŸō/ – The right starting “cell” but with the long “i” like saying “I owe”

/selūŸlō/ – Almost like cellulose, without the “se”

/silēō/ – That is just silly

/CHelyō/ – A clever shout out to a friend?

/Kelēō/ – There are times that a “c” sounds like a “k”

/Kēlō/ – Which is a nice metric reference to “kilo”

 

Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available in place today. There is a saying that you should “Inspect what you expect”.  Nothing could be more true than pronouncing the name correctly!

Overview

As organizations experience success with the reporting/monitoring from their initial IIoT implementation objectives, their thoughts and questions naturally turn to how many devices and how many different things they can put on the same platform to inform them of other aspects of their operations. In fact, the relatively low cost to track additional nodes on the installed platform makes them wonder what they “can’t” remotely monitor and control. These are some of the initial questions.

cellio_wireless3

How Many Things can be Monitored at Once?

Without consideration for distances (but assuming the Transceiver nodes can talk to at least one Gateway device), hundreds and thousands could conceivably be connected to a single Gateway in a given installation. Factors that would play into the maximum number of nodes would have to consider the configuration parameters of the devices, but could be configured to support a significant number of devices. Additionally, since the Transceivers can connect to up to 16 points, the actual number of “things” that can be monitored is an order of magnitude greater.

 

How Many Different Kinds of Things can be Monitored?

Again, without consideration for distances (but assuming the Transceiver nodes can talk to at least one Gateway device), any manner of device that produces (or could be made to produce) an electric signal can conceivably be sensed and the measurement recorded and reported/monitored. If something doesn’t currently produce an electrical signal, some means of measuring the state of the device would need to be put in place so that the Transceiver could gather the information and transmit it electronically. For example, some devices may already be installed that produce a signal (a light switch can be monitored to see if the light is on/off since it is already electric). An alternative example would be measuring the light intensity of the sun – in this case a photocell could be put in place and could measure the light level and the Transceiver would measure the signal from the photocell and report it.

 

How Many and How Different of Things can be Controlled?

Similar to the monitoring noted above, different approaches can be employed to control something from the range of a simple single digital signal (ON/OFF) to the more complex RS-485 communication with a Programmable Logic Controller (PLC). Thus, there is support for a large number of devices across a significant range of device types.

 

 

Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available in place today. There is a saying that you should “Inspect what you expect”.  If, like many organizations, your organization is diving into remote monitoring across a facility, a process, or the entire enterprise, having an extensible platform that is easy, quick, and inexpensive to deploy that supports the broad range of existing and future devices that need to be monitored and controlled, test Cellio on your tougher challenges to make sure you have the best platform in place for today and into the future.

Overview

One of the significant expense items associated with installing IIoT comes from the costs associated with installing the equipment. In particular, pulling cables and power cords (and conduit) can be on the order of half of the expense of the total installation. In the case of Cellio, the Transceivers run off a 9VDC battery that can also be used to power sensors – thus removing the need for power, cables, and conduit in many applications. Even in those cases where power may be needed for the sensing device, the Transceiver does not need a separate power supply to be provided (making retrofit installations very cost effective and quick). The Cellio Gateway can run from directly from a small solar panel or it can be plugged into an existing power plug within range of the Cellio Transceivers.   These wireless aspects of Cellio (resulting from lower installation, operation, and maintenance costs) further reduce the overall cost of ownership for Cellio based IIoT installations.

cellio_wireless1

 

Look Ma, No Power Cables

In one example installation, there are over 1,000 stationary objects that need to be monitored and measured. These objects are out in fields where pulling power, conduits, and cables would be on the order of $1,500 per object. The quick math for this scenario is $1,500 * 1,000 => $1,500,000 or $1.5M! Obviously this calculation does not account for the project management, logistics, associated back-end costs, monthly bills for electricity, or any other costs for maintenance, etc. But at first order, it is useful to demonstrate the benefit of a truly wireless system like Cellio. In the case of Cellio, the Transceiver has a 9VDC battery (Lithium Ion preferably), that can provide power and report readings from an external sensor for up to a 5 years. Thus, the installation costs (and associated annual maintenance, etc.) is reduced almost to $0. Additionally, in those cases where a sensor is already in place (whether it is unpowered or powered), the Transceiver can simply be placed on or nearby, connected to the sensor, and immediately start reporting the sensor readings wirelessly and remotely – no power supply or wires required.

cellio_wireless2

 

 Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available in place today. There is a saying that you should “Inspect what you expect”.  When minimal installation costs, operational costs, and remote regular reporting and monitoring are important to the business, Cellio should be one of the first considerations. Be surprised when you see for yourself!

cellio_wireless3

 

Overview

From Agriculture to Manufacturing to Industrial Processing, there is at least one common challenge for remote monitoring – substantial distances. In addition to the distances, obstacles that block line of site between points of interest compound the challenge for transmissions and communications. Also, most of these points don’t have electrical outlets conveniently accessible. Cellio provides a solution to these challenges with its 9VDC powered 900MHz LoRa Transceiver devices that can collect information from remote sensors and transmit them over great distances through a great number of objects and materials – to the pleasant surprise of many process and facility owners/operators.

cellio_distance1

 

IIoT Remote Distances

In industrial, agricultural, and other environments that have process elements that require going outside of a single facility, distances are typically measured in thousands of feet and hundreds of yards/meters. These environments are typically not well suited for pulling and maintaining long lengths of conduits, cables, and power – especially when costs are considered. In these cases a wireless solution that can inexpensively, quickly and reliably transmit information from a remote point B to a central point A without having to provide a power outlet is most desirable. Cellio Transceivers accomplish this using 900MHz LoRa (Long Range) wireless technology to cover great distances and transmitting through a great number of obstacles that would traditionally block communications for other approaches.

cellio_distance2

 

IIoT Remote Power

Further challenging the requirements for an acceptable/feasible solution, not having access to a power plug means that the sensors and the transmission have to provide their own power source – and ideally that the power source will last longer than a year before having to be maintained/replaced. Cellio Transceivers accomplish this using a 9VDC battery that can be used to power connected sensors and in typical use can provide remote data for up to 5 years on a single battery before having to be replaced.

cellio_distance3

 

IIoT Remote Network Access

The typical geographical locations of many agricultural, manufacturing and industrial operations are in more rural/remote locations. To access the internet and other remote networks, wireless is required to transmit all of the collected data to the “back-end” where the data can be aggregated, computed and distributed to users and systems that can make use of the remote monitoring information. Cellio Transceivers and Gateways accomplish this using Cellular CDMA/GSM network infrastructure to move data from the site to back-end data storage and processing. From the back-end, a host of operations, alerts, and computations can be generated to inform users and processes of the status of equipment, inventories, and process parameters.

cellio_distance4

 

Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available in place today. There is a saying that you should “Inspect what you expect”.  The distances typically involved in Agriculture, Manufacturing and other Industrial operations require technology designed and well suited for these environments. Cellio provides all this capability and more out of the box.

Overview

If a device fails in the field, and no one was there to see it – it still failed. When will it be fixed? Could it have been fixed before it failed? Technologies like IIoT can provide data, information, and insights about equipment that is failed or failing so that it can be addressed reactively, or proactively, depending on the priorities of the maintenance and repair policies of an organization.

cellio_insights1

 

IIoT Insights – Simple

The very simplest insights that an IIoT system can provide are those that report a change in “normal status”. These can be immediate triggers that provide alerts about something failing, something going beyond a set limit, or something returning to a known good state. No matter the application, the information is a “snapshot” view of the state at a moment in time. The upside to this kind of information is that it is immediate, and it is reporting a real thing in the real world that needs to be addressed NOW. However, if the item being monitored is critical to the operation of the facility, it would be more useful if the information could be used to warn of an impending failure so that the failure can be avoided altogether.

cellio_insights2

 

IIoT Insights – Complex

The more complex insights that an IIoT system can generate are those that consider more than a single data point comparison – usually including some advanced calculations or analytics. In these cases, a trigger or alarm can also be generated, but the condition can alert the appropriate users to conditions that may be leading to a failure. For example, for some refrigeration units, the parameters (current draw, cycle times, etc.) of a good working unit is known. Thus, if the refrigerator is drawing more current or cycling more frequently than it should, this information can be used to alert the users that there is an issue with the refrigerator that needs attending to so that the refrigerator does not fail catastrophically.

cellio_insights3

 

IIoT Insights – Visualizing

In both simple and complex scenarios, all the data collected and transmitted to the back-end can be visualized in any number of ways. For many users, a real world mapping of the items with various color codes and labels is sufficient for their needs. Others need very high level summary table views, while still others need detail views of all the variables. Because the information from the remote devices is centralized in the back-end, all this information can be graphed, mapped, calculated, coded, and displayed however the users like to match their specific needs. They say a picture is a worth a thousand words – a visualization of data may be worth much more than that!

cellio_insights4

 

Bonus: IIoT Insights – Remote Control and Remote Signaling

Of course, once the users have the insights, most times they will want to do something about the situation. In the IIoT system Cellio supports, there is also the option to send control data back to the field to control indicators, equipment, etc. For example, imagine that a refrigerator was detected as failed or failing, not only could an email or SMS be sent to a distribution list of people that worked with that refrigerator, but an alarm could be turned on near the refrigerator to alert people in the area that it needed attention immediately. This ability to manually or automatically send and control information to the alarm (light, buzzer, or otherwise) allows the IIoT users to “complete the loop”.

cellio_insights5

 

Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available in place today. There is a saying that you should “Inspect what you expect”.  With insights from the IIoT system, users can inspect all of the monitored items at all times. Additionally they can be alerted when items fail or when conditions may indicate and impending failure. And to close the loop, the system can generate a response to the situation that could be gated by a human or send automatically. Cellio provides all these capabilities and more out of the box.

Overview

We have heard a number of customers say the following phrase, “because we don’t have someone there watching it all the time.” And for equipment and supplies that are critical to the operation of the business, certain failures need to be identified as soon as they happen (if not before). With inexpensive devices that can be placed in and around the assets in an operation, the ability to monitor devices in real time can provide insights that could be used for advance notification as well as notifying anyone/everyone involved so that critical issues can be resolved as quickly as possible. In some ways, not only can the Cellio IIoT devices help to make and save money, they can also be considered as inexpensive insurance.

cellio_insurance1

 

IIoT Devices to Identify Issues Before, During, After Failure

The very nature of IIoT devices deployed in a distributed manner in and around the assets in the operation translates into constant monitoring. What is monitored, and how, is critical to generating the information that can be used to determine if things are within, if they are trending out, or if they have exceeded acceptable operating parameters.   Armed with this information, critical elements in the operation can be remotely monitored, reported, and produce notifications to equipment and process owners for preventative maintenance and issue resolution. Most importantly, if the issue is located in a place that is not typically monitored in some other way, the IIoT device can assure that if something goes awry that someone gets notified – immediately. The IIoT device, via the sensor, detects the “out of bounds” condition, generates an alert that is relayed via the Gateway device to the back-end. The back-end evaluates the state and based on the priorities and settings of the organization, notifies those people and resources appropriate for the response. If used for collecting data regularly about the state of the equipment (or inventory level), the information could notify relevant stakeholders about potential issues that could lead to a failure before the failure occurs. Depending on the impact of a failure, detecting it in advance might be more valuable then simply fixing things after they fail.

cellio_insurance2

 

Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available in place today. There is a saying that you should “Inspect what you expect”.  If someone isn’t able to watch critical resources 24×365 having affordable devices that are watching the critical resources may very well be the best option for assuring and insuring that issues are detect and resolved as early as possible – ideally averted all together. When you consider that these humble devices can be deployed and provide alerts to situations that could cost Million$, you might start to wonder if a case could be made to an insurance company for reduced premiums.

Overview

They say, “what gets measured gets done”. This is no truer than in IIoT installations where the saying might be adapted to “what gets measured gets reported, regularly”. In fact, there are a growing number of stories where some frontline workers and some managers have initially been reluctant to have IIoT devices installed – the additional visibility that comes from devices regularly reporting measurements may expose practices that are inefficient and detrimental to operations and net profits. In time, reluctance turns into relief.

cellio_returns1

 

Using Ingredients in the Correct Order

In many businesses, research and experimentation has been done to determine the best order in which to use ingredients. However, in practice, where there is not enough oversight or attention paid to the level or order of ingredients, the ingredients may be added or used in the incorrect order. The net result of the use of ingredients in the incorrect order can be sub-optimal sizes, durability, or value of the resulting product. Ultimately, across many production sites and many batches, this amounts to significant losses in profits. IIoT devices installed and monitoring can identify those areas in which ingredients where not fully utilized or used in the incorrect order to notify business owners of opportunities to address “best practices” as quickly as possible and the information can be leveraged as a “teaching moment”. Ultimately, if and when the workers and managers get on-board, they can leverage the IIoT devices to increase their own visibility and validate their adherence to the standards. The real “win” is when they decide to become partners in evaluating additional areas and opportunities to improve results.

cellio_returns2

 

Ordering Ingredients in Time (Risk of Running Out)

Associated with using ingredients in the wrong order, we have seen where ingredients that are running low are not re-ordered in time. In the worst case, this can have catastrophic impacts on the current production batch (where everything has to be destroyed and disposed) or at best case an emergency delivery (with all the additional “rush” charges, overtime, and lost productivity) is delivered in time to keep things running with no interruption. In the spectrum between “destruction and interruption” there is a wide range of losses that are incurred. With IIoT devices in place, potential issues related to ingredients running low can be identified early and addressed in a timely (and cost effective) way. Most importantly, this information does not rely on someone remembering to check the levels or rely on them to measure the levels accurately and consistently. The dependability of the IIoT generated measurements becomes the primary input – with full expectation that workers or process owners will audit the measurements regularly to confirm the IIoT provided measurements.

 cellio_returns3

 

Timely Reporting of Equipment Failures

If there isn’t a predictive maintenance program in place to adhere to scrupulously, the next best thing is to have IIoT devices monitoring equipment to detect the moment that operating parameters have gone outside acceptable ranges. This real-time, and near-real-time, information can be the difference between knowing things are running well and hoping that things aren’t failing. For example, a simple water pump required to keep process equipment cool could fail and then minutes or hours later critical equipment that depends on the cooling water can fail bringing the whole operation to a halt. With IIoT devices monitoring the water pump, these early risks can be detected immediately and addressed before they turn into irreparable damage and guaranteed extended downtime. With the relatively small expense of the IIoT devices, significant increases in income can be realized.

cellio_returns4

 

Bonus: In Depth Detailed Analytics

Extra benefits come from having IIoT devices collecting data from multiple aspects of the industrial processes, supplies, and logistics for future analyses. While the immediate benefits are in the instant visibility to levels and measurements, the longer term benefits will come from collecting a data history and correlating the data with other environmental variables to uncover hidden factors and validate any proposed improvements. For example, in one case, it was identified that the weather had a direct and measurable impact on the rate of update of various ingredients. With this insight, future production runs now take into account weather reports to adjust ingredient inventories. In yet another case, data was analyzed to see why certain sites were producing more optimized results, it was determined through the data across all sites that the suboptimal site was failing to fully utilize one ingredient before switching over to the subsequent ingredients. All of these findings demonstrated real losses in revenue and net income. Based on the findings, both revenues and income were increased without any indirect or unintended consequences.

cellio_returns5

 

Conclusion

The Cellio Wireless Network has been designed to be quick, affordable, and high quality. Cellio Wireless Transceivers allow the Cellio system and customers to quickly and easily expand existing systems with as many sensors and controllers as they like (with minimal incremental expense).  The data collected in the back-end data system can be easily and rapidly mapped and provided for view on PC’s, tablets, smartphones, etc. both via browser views as well as automatically generated native mobile app views. Sharing and modifying the dashboard views is quick and easy. All of this is available in place today. There is a saying that you should “Inspect what you expect”.  In many cases, the recommendations provided by corporate groups and third parties is well-researched and valid.   From the conveyance of the information to putting it into practices that are adhered to, there is a wide range of implementation success and compliance. Is it any wonder that outcomes are also so widely varied? With IIoT devices, the data from across all sites, all production runs, and various operators and managers can be gathered, viewed, compared, and analyzed. As we find most frequently, it isn’t that workers and managers don’t care, they just have so much on their plates that they can’t pay attention to everything, nor all at once. When no one else is able to pay attention to critical measurements, you can count on Cellio.

cellio_returns6