Optimising production efficiency in small and medium enterprises with IoT-driven automated jerry can filling systems

This paper presents a cost-effective, IoT-based automated filling and capping system tailored specifically for small and medium-sized enterprises (SMEs). The solution leverages open-source Arduino controllers, modular hardware, and advanced sensor integration, including ultrasonic and infrared sensors, to enable precise, real-time operational adjustments. While traditional automation technologies such as PLCs and SCADA remain widely used in industries, this system offers a more affordable alternative, providing superior scalability, flexibility, and ease of maintenance. Comprehensive operational and field testing, supported by statistical analyses, demonstrated substantial improvements including a 60% increase in throughput, an 85% improvement in filling accuracy, and halving material waste and downtime. Economic analysis further validated the financial advantages, highlighting a rapid return on investment. Operator feedback emphasised its reliability and intuitive interface. By integrating real-time monitoring, adaptive control algorithms, and predictive maintenance capabilities, the developed system establishes a new benchmark for accessible, efficient, and scalable automation solutions suitable for SMEs.