Skip to main content
Centre for Innovation & Consultation

VL DPM: Digital Production Management System

Dr. Muhammad Firdaus Akbar Jalaludin Khan

Assoc. Prof. Dr. Bakhtiar Affendi Rosdi

Dr. Mohd Nadhir Ab Wahab

Most Malaysian SMEs still practice paper-based manufacturing execution. Schedules, job orders, quality reports, and packaging lists are paper-based instructions. Operators' work progress, including machine performance, quality reports, store, and warehouse inventory, are not being monitored in real-time. Thus, an integrated digital system is required to maximize the output and to fulfill the need of Malaysian SMEs for the adoption of Industry 4.0. VL DPM, an integrated digital system adopting Industry 4.0 technologies digitalizes the entire production planning and execution; it covers the digitalization of receiving raw material activities up to the delivery of the finished goods.

Problem Statement

  • A paper-based approach means inefficient processes, poor handling of raw materials, and production execution.
  • The management has difficulties making immediate decisions for any newly received orders.
  • The machines and manpower are under-utilized due to a lack of real-time performance monitoring.
  • Lack of incoming quality control and product traceability.

Novelty and Inventiveness

  • VL DPM is an artificial intelligence-driven smart scheduling that auto-assists the planner to plan the production execution.
  • VL DPM offers fully integrated modules, thus the client can have full traceability of the product via the data analytics features.
  • VL DPM allows customization to suit the client production operations, it is not restricted to a number of users and offers low subscription fees.

Applicability and Benefits

VL DPM consists of 5 modules, and the framework includes both hardware and software deployment to provide fully automated production planning and execution:

  • Raw Material Stock Management Module.
  • Production Planning & Scheduling Management Module.
  • Production Execution & Machine Management Module.
  • Quality & Quantity Control Management Module.
  • Parts & Product Warehouse Management Module.

The system aimed to control and monitor incoming quality control, manage resources efficiently, plan the job, and automatically integrate into different production stations, including quality and warehouse.

The system monitors overall equipment effectiveness (OEE) in real time as a machine performance indicator. The real-time OEE indicator ensures the company uses existing machines and manpower to their total capacity and increases efficiencies in their production lines.

Research Achievement

  • Grants: 10 research grants related to automation, AI, and digitalization.
  • Journal Publication: 10 published journals related to automation and AI.
  • No of Students: 1 Ph.D., 1 MSc, 4 Undergraduate.

Commercialization Potential And Industrial Partner

To date, the current revenue for VL DPM is RM 823,600 with 4 corporate clients. The revenue stream is from system development costs, annual subscriptions, and training.

Several plastic manufacturers are subscribing to VL DPM. The existing clients are:

  • Spen Industries Sdn Bhd.
  • EHP Industries Sdn Bhd.
  • Waner Plastic Manufacturing Sdn Bhd.
  • Binsen Plastic Industry Sdn Bhd.

Intellectual Property Status

  • Copyright, CRLY2021P05902, Digital Production Management System.
  • Copyright, CRLY2021P05901, Integration of PLC Automation with Microcomputer.

Status of Invention

VL DPM has been deployed and proven in an operational environment (TRL 9). A start-up company Visionlytics Sdn Bhd from USM has been formed to commercialize the VL DPM and offer services to local SMEs.

Impact of Innovation

  • Government: Promotes MySTIE 5 and SDG 9 fostering innovation as part of our Malaysia Madani aspiration.
  • Economy: Spur economic growth in Malaysian SMEs with the adoption of Industry 4.0 technologies.
  • Society: Created 6 high-value job opportunities and 12 technical internship placements.
  • Academia: Income generation to university via a technology licensing fee.
  • Industry: Optimize the usage of resources and increase the production rates.
  • Environment: Demonstrate Malaysia's commitment to environmental responsibility via digitalization.
Back to Product List