Achieving a Paper-Lite Facility with Enhanced Data Analytics

Challenges

1. Data-Driven Decision Making: Ardent Mills needed to leverage data to continuously improve operations. This required systems to collect and analyze data from various plant components to detect predictive failures and optimize maintenance.
2. Analytics for Smarter Production: To achieve modern, high-tech production, Ardent Mills needed to harness analytics. The goal was to use data for formula adjustments to optimize blends, ensuring higher-quality products and making production smarter and leaner.
3. Paper-Lite Facility: The goal was to transition from paper to electronic data collection and processing. They aimed to eliminate manual data entry, improving efficiency and accuracy.
4. Integration and Visualization: Ardent Mills needed integration with their existing systems and visualization tools. The solution had to ensure seamless data flow and user-friendly interfaces for real-time analysis.

Solution

Interstates initiated planning almost three years prior to this project, collaborating with stakeholders to develop a comprehensive plan for achieving a paper-lite facility and maximizing data collection. Key solutions included:

• Operational Technology: Designed a robust network architecture to handle 2,500 connected devices, collaborating with Ardent Mills IT and Microsoft to develop data storage standards.
• Industrial Analytics: Developed applications for item and recipe management, enabling predictive formulations and better product quality. Implemented Near Infrared (NIR) Spectroscopic measuring devices for grading factors and bin temp monitoring for environmental control.
• ERP Integration: Enhanced ERP system integration to eliminate dual entry and automate data collection for EPA reporting. Developed an app to collect data automatically and generate the necessary reports.
• Data Visualization: Provided tools for data visualization, allowing Ardent Mills to monitor and analyze real-time data effectively. Interstates’ industry experience and close relationship with the client facilitated smooth construction for data collection, ensuring all data requirements and client requests were met.

Return on Investment

The implementation of these solutions resulted in significant improvements for Ardent Mills:

• Predictive Maintenance: As the systems get put in place, the mill will eventually be able to predict equipment failures and perform necessary maintenance, reducing downtime and enhancing operational efficiency.
• Enhanced Product Quality: Access to real-time data and predictive formulations allows for precision blending, improving the consistency and quality of the products.
• Operational Efficiency: The automated data collection and integration with the ERP system streamline operations, reduce manual entry errors, and ensure compliance with EPA regulations.
• Intelligent Decision-Making: The extensive data collection and analysis capabilities enable smarter, data-driven decisions, optimizing production processes and enhancing overall plant performance.

Since the plant’s initial start-up in 2022, Interstates has worked closely with Ardent Mills to refine and optimize data usage. By leveraging historical and real-time data, the plant has improved operational efficiency and product consistency. Interstates’ I-Control software continues to provide valuable insights, allowing for real-time adjustments and informed decision-making.

This collaboration highlights the innovative potential of data analytics in transforming production facilities, ensuring high product quality and operational efficiency. Moving forward, Interstates and Ardent Mills will continue to evolve the system, centralizing data to enhance decision-making and drive future improvements at this and other plants.