Manufacturing Module

Digital Twin for Palm Oil Milling

Transform raw machine data into actionable intelligence. Predict bearing failures before they happen, automate shift handovers, and eliminate un-planned downtime — all processed securely at the edge.

Interactive Control Desk

Interactive Process Visualization

An interactive piping and instrumentation diagram. Engineers can click any node to inspect live telemetry, track fluid flow, and triage anomalies in real-time — all from a clean, web-based interface.

MillOS SCADA Dashboard featuring Industrial Clarity UI

Industrial Clarity UI: High-contrast, data-dense canvases built for control rooms. User-initiated navigation prevents motion sickness.

Analytics Engine

OEE Bottleneck Intelligence

Root-cause attribution meets conversational BI. The AI proactively pushes OEE drop alerts to WhatsApp, then lets executives drill down with natural language interrogation.

Overall OEE

81.1%

↑ 2.1% vs last week

Availability

89.2%

14 downtime events

Performance

93.7%

Minor speed losses

Quality

97.1%

0.3% rework rate

OEE Loss Waterfall — This Week

100%

Planned

-3.2%

Planned Stops

-7.5%

Breakdowns

-4.1%

Speed Losses

-1.9%

Defects

-2.2%

Short Stops

81.1%

Actual OEE

📊 Peringatan OEE — Plant Alpha

OEE minggu ini turun ke 65% (target: 85%).
Penyebab utama: Availability Losses.

Boiler 2 mengalami 14 kejadian downtime tak terencana.07:00

Kenapa availability turun?07:02

Boiler 2 mengalami 14 kejadian downtime tak terencana minggu ini. Mayoritas disebabkan oleh tekanan uap rendah.07:02

Kenapa Boiler 2 sering gagal?07:03

💡 Analisis Akar Masalah:
Tekanan uap rendah disebabkan oleh kelelahan seal katup. Bearing terakhir diganti 8 bulan lalu (umur pakai: 12 bulan).

📎 Rekomendasi: Jadwalkan penggantian saat shutdown terencana (3 hari lagi).07:03

Conversational BI — drill down with “Why?”

🚨 Anomali Terdeteksi

Press #3 — Bearing Drive End
Getaran: 0.92G (threshold: 0.5G)
Skor Anomali: 0.89 (Isolation Forest)
Puncak FFT: 147 Hz — indikasi keausan inner race

📎 Buka Dashboard SCADA →14:22

Ack. Jadwalkan inspeksi besok shift 1.14:25

Anomaly alert with deep-link to SCADA

Platform Architecture

Edge-to-Cloud Digital Twin

A deterministic 3-tier architecture that guarantees sub-50ms processing for mission-critical machine states, while bridging global analytics in the cloud.

Tier 3: Enterprise Cloud

Global Digital Twin platform. Aggregates multi-site data, trains predictive ML models (e.g. LLM/RAG for operational queries), and powers the executive control desk.

Global Analytics

OEE Reporting

Tier 2: Fog Engine (MillOS)

On-premise industrial PC running high-frequency TimescaleDB. Executes real-time Finite State Machines (FSM) to calculate OEE without internet dependency.

Sub-50ms Latency

Timescale HA

Tier 1: Edge (Naya Sense)

Hardened IoT endpoints parsing raw PLC protocols (Modbus, OPC-UA) and analog sensors (4-20mA, vibration) directly from the mill floor. Streams UDP binary formats.

10Hz Sampling

Modbus RTU/TCP

MQTT/UDP

Visual Interface

Inside MillOS

High-fidelity interfaces built for industrial clarity, designed to be legible on the factory floor and comprehensive in the control room.

Estate-wide GIS & Asset Tracking

Predictive Vibration & FFT Analytics

High-Contrast Control Room Dashboard

Logistics & Loading Gate Management

Key Capabilities

Why MillOS

Dual-Origin Predictive Fusion

Stop choosing between machine data and human context. Naya fuses high-frequency SCADA telemetry (vibration, heat) with unstructured WhatsApp field chatter. Correlate machine stress with operator voice notes to build true predictive maintenance models and ground-truth validation.

3x fewer false positives

Predictive Maintenance

Isolation Forest ML + FFT vibration analysis detects bearing failures 3+ days before breakdown. Schedule repairs during planned shutdowns.

$7,200/month saved per prevented shutdown

Sandboxed Edge Analytics

Need a custom vibration analysis script? Naya writes deterministic Python scripts and deploys them directly to the Edge inside Sandboxed Docker Containers, ensuring safe, real-time telemetry processing without risking core systems.

Sub-10ms processing latency

OEE Waterfall Analysis

Automatic root-cause attribution across Availability, Performance, and Quality. Drill down via WhatsApp or dashboard.

510 person-hours/year saved on shift handovers

Ready to Build Your Digital Twin?

See how MillOS transforms palm oil milling operations with edge-native AI.

View Use Cases ← Back to Platform