A comprehensive mobile data collection and management system for industrial applications

Abstract

Industrial organisations rely on quality information to remain sustainable in competitive markets. To obtain high quality information, data must be collected and processed in an accurate and timely manner. Many automated systems have been developed to actively monitor industrial systems and record data. However, automated data acquisition systems are often costly to implement due to high infrastructure costs. Furthermore, typical systems are limited to a fixed range of measurements and do not support event-based data collection. Due to the shortfalls associated with automated data acquisition systems, industrial organisations implement alternative methods to collect data. These alternative methods include manual handwritten notes, which involve significant amounts of human interaction with data. Consequently, the collected data is error prone and cannot be used as credible data sources. Data collected through manual human methods are therefore not suitable for audited applications. Mobile data collection systems offer a possible solution, however no single system that offered a comprehensive solution that addresses all the identified industrial data collection needs was found. A novel mobile data collection and verification system was therefore developed to collect data related to industrial activities. The developed system provides users with a generic framework that can adapt to individual data collection needs. Furthermore, the developed system implements a unique combination of components that improve data accuracy, ensure full traceability and provides assistance to users on various levels. The novel system was created by combining both new and existing components to form a single comprehensive data collection and management system. These components include data verification, version control, calculation and data validation, task management, system restriction and user support, as well as data processing and integration. These components interact with one another to form a integrated solution that addresses the industrial data collection needs. The system was implemented at numerous industrial sites throughout South Africa, including a steel production facility, water utilities and mines. The range of data collection applications include plant maintenance on steam networks, compressed air networks and water networks, validated water meter readings, electricity meter readings and a range of specific audits. The system was integrated with client systems to enable automatic data handling according to client specifications. Various users utilised the system to capture data at the aforementioned facilities. Efficiency improvements were observed during the data collection, consolidation and reporting, as well as the action phases. The system also improved the accuracy of collected data. This was achieved through real time data verification, user guidance and task management structures. Accurate data with advanced measurements was used to improve client processes and produce high quality data sets that can be used to base important decisions on.