Simbiosis × Hawle Özkan - Industrial data & integration
Paint consumption tracking and ERP integration
Industrial load cells under the powder paint buckets weigh consumption continuously, to the gram. Every gram is written to the active work order and posted to the ERP the moment the job closes. Weighing, not guessing.
Results - in figures
86,400 readings a day: consumption is calculated by the scale, not by estimate
Consumption records to the gram, 100% matched to work orders
Manual data entry gone entirely: no paper, no Excel, no guesswork
Costs land in the ERP as soon as the work order closes; month-end close takes minutes
Powder paint is one of a paint shop’s biggest consumables, and in most plants consumption is still recorded by guesswork. In this project the paint buckets were placed on weighing platforms with industrial load cells: consumption is the difference between two weighings. A job started/finished signal is taken from the machine, and every gram measured is written to the active work order immediately; the moment the job closes, the total consumption is already posted to the work order in the ERP, without anyone typing a thing. Smart pattern recognition automatically filters out abnormal signals such as vibration and bucket refills, so abnormal data never makes it into a report. On the ERP side we use a pull architecture: data isn’t pushed, it is served within seconds whenever the ERP asks for it.
01 - Challenge
The challenges
The starting point: what was slowing the line down, putting it at risk or keeping its data in the dark?
- 01Challenge
Cost accounting that drifted with manual weighing and end-of-shift Excel records
- 02Challenge
Vibration, bucket refills and bucket changes distorting the raw weight signal
- 03Challenge
Integrating with the customer’s existing, closed ERP system
- 04Challenge
100% accuracy and integrity in data transfer, despite fluctuations on the plant network
- 05Challenge
Fitting the sensors without stopping production
02 - Solution
Our solutions
Our answer: mechanics, controls and software, built by one team.
- 01Solution
Industrial load cell platforms with gram-level precision installed under the buckets
- 02Solution
Pattern recognition: data is frozen during vibration and the baseline is recalculated after a refill, so a negative consumption line is never written
- 03Solution
Custom middleware plus OPC-UA communication for the ERP integration
- 04Solution
Buffering and validation to guard against data loss
- 05Solution
A pull-based API: the ERP fetches consumption by work order whenever it wants
03 - Result
The results
The difference measured on the line, and seen by the customer every day.
- 01Result
86,400 readings a day: consumption is calculated by the scale, not by estimate
- 02Result
Consumption records to the gram, 100% matched to work orders
- 03Result
Manual data entry gone entirely: no paper, no Excel, no guesswork
- 04Result
Costs land in the ERP as soon as the work order closes; month-end close takes minutes
- 05Result
Quotes are priced on real consumption data, not on gut feeling
04 - System
Project highlights
- Continuous weighing: one reading per second, 86,400 records a day, 24/7
- Real-time consumption tracking by work order: every gram has an owner
- A smart data filter that recognises vibration and refill patterns
- Visual reports by work order, day, kg and cost
- Pull architecture: data is ready within seconds whenever the ERP asks
- Manual data entry removed entirely
Technologies used
05 - On site
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