Silo-level alert before the reorder threshold

Background

An ingredient handling operation needs to know how much material remains in its silos. The level informs purchasing and production, but the existing check depends on someone climbing to look. Our monitoring brings that reading into a shared view so both teams can follow inventory as it changes.

The problem

A manual check captures the silo at the moment someone reaches it. Between checks, the reading ages while material continues to be used. The estimate also depends on the person making it. That leaves the teams planning around a periodic observation and requires another climb whenever a fresh check is needed.

How we found it

We use non-contact radar level sensors on the silos and follow their readings continuously. A configurable reorder threshold gives the level trend an operating reference. Low-level alerts go to purchasing and production, putting the same change in front of the people arranging supply and the people planning the work that uses it.

What changed

The manual level check is replaced by a continuous reading. The teams can see the current level and receive an alert before inventory reaches the reorder deadline. They share the same reference when discussing replenishment, instead of relying on separate requests for someone to climb the silo and report what they find.

The lesson

Make the reorder threshold visible to purchasing and production, and send alerts to both teams. Use the level trend between deliveries to check that the threshold leaves enough time to arrange the next supply.