Cooperation Project for the Cofco Factory Site Staff Location Management System

I. Project Background

Feixian COFCO Oils & Fats Industrial Co., Ltd., a core subsidiary of the COFCO Group, was established in 2004. Leveraging the resource advantages of the Yimeng Mountain region—the nation’s major peanut-producing area—it has grown into a modern industrial facility integrating edible oil processing and plastic product manufacturing. The company currently employs over 330 staff members, with business operations spanning:

Edible Oils Segment: Produces over 50 varieties of oils, including peanut oil and soybean oil under the “Fulinmen” and “Lumeng” brands, with an annual production capacity exceeding 100,000 tons.

Plastics Products Segment: With an annual production capacity of 80 million sets of PET preforms, caps, and other components, it provides customized packaging solutions for “Fulinmen” small‑packaged edible oils, as well as for the pharmaceutical, chemical, and beverage industries.

As the company grows in size, its traditional personnel management model is facing the following challenges:

High safety risks: In high-risk areas such as the filling workshop and solvent storage zone, unauthorized personnel entering or lingering in these zones is difficult to control.

Low management efficiency: Cross‑workshop personnel scheduling relies on manual data collection, with attendance error rates exceeding 15% and delayed emergency response.

Challenges in production coordination: Visitors and employees share the same spaces, and there is a lack of data to support assessments of personnel density and dwell times in critical equipment operation areas.

Significant compliance pressure: Must comply with the mandatory requirements of the “Standardization Specification for Safe Production in Chemical Enterprises” regarding personnel positioning and electronic fencing.

To address the aforementioned challenges, our company has leveraged integrated indoor–outdoor Bluetooth positioning technology and aligned it with COFCO Oils’ requirements for “safe production + lean management,” custom‑developing a “Personnel Positioning and Intelligent Control System” tailored to the plant site. This system enables comprehensive, real-time monitoring of personnel, vehicles, and visitors across all areas.

II. Cooperation Objectives

Enhanced Safety Management: Enables precise personnel positioning within the plant area at an accuracy of 3–5 meters, with 100% early warning for risks such as unauthorized entry into high‑risk zones or prolonged presence in restricted areas.

Production synergy and efficiency gains: By leveraging personnel distribution heatmaps to optimize workshop scheduling, equipment utilization has increased by 20%.

Accelerated emergency response: Within 30 seconds of an incident, personnel locations are pinpointed, and nearby cameras and emergency public address systems are activated in coordination.

Compliance Management Implementation: Meets the assessment requirements of the “Standardized Safety Production Specification for Chemical Enterprises” regarding personnel positioning, electronic fencing, and trajectory tracing.

Visitor Management Optimization: Real-time monitoring of visitor movement, with automatic alerts for unauthorized area access, helping to mitigate enterprise risks.

III. Technical Solution

1. Hardware Deployment

Bluetooth Beacon:

Model: FY-BLE-C30 (Industrial‑Grade Explosion‑Proof)

Deployment Strategy:

Indoor: Workshops and warehouses are equipped at intervals of 30–50 meters, with denser deployment—every 15 meters—in critical areas such as the solvent tank farm.

Outdoor: Beacon deployment along factory roads and parking lots at 80-meter intervals, with a total of 186 beacons installed;

Technical specifications: Protection rating IP67, 40% improved resistance to metal interference, supports wide-temperature operation from -30°C to +70°C, and meets explosion-proof rating Ex d IIC T6.

Badge-style locator:

Model: FY-BLE-T20 (Employee Version / Visitor Version)

Features:

Positioning accuracy: 3–5 meters (integrated indoor–outdoor positioning, supports floor switching);

Safety and Protection: IP68-rated water and dust resistance, withstands drops from up to 2 meters, and offers a battery life of ≥45 days.

Alert Function:

SOS One-Click Alarm: Press and hold for 3 seconds to initiate an emergency call, which will send your location to the central control room and the security officer.

Idle alarm: If the device remains idle for more than 20 minutes (customizable), a Level 3 alert is triggered (badge vibration → SMS push → Tel / Whatsapp notification);

Overcrowding Alert: Automatic alerts are triggered when the personnel density in a designated area exceeds the threshold (e.g., ≤15 people in the filling workshop).

Access Control: Employee cards grant access throughout the entire plant, while visitor cards can be configured with temporary access zones (e.g., office buildings, reception areas).

2. Positioning Technology

RSSI–Fingerprint Algorithm Fusion for Positioning:

Indoor positioning: Based on a Bluetooth RSSI fingerprint database and inertial navigation, combined with a workshop 3D model to construct a positioning model, with an accuracy of ≤3 meters.

Outdoor positioning: By leveraging LoRa signal fingerprint matching and GPS‑assisted localization, the positioning accuracy on plant‑site roads and in parking areas is ≤5 meters.

Inter‑zone switching: By integrating a barometric pressure sensor with signal strength variations, the system automatically detects indoor–outdoor transitions and floor changes, with an accuracy of within one floor.

IV. Core Functional Modules

Functional moduleFunction DescriptionTechnical Implementation

Real-time personnel positioningReal-time display of personnel locations across the entire plant, with support for hierarchical visualization on 3D maps (e.g., workshops, warehouses, office buildings).Based on the integration of GIS maps and Bluetooth positioning data, with an update frequency of ≤3 seconds, it supports filtering by department and job type.

Trajectory Playback and StatisticsSupports 30-day historical trajectory queries and generates personnel activity heatmaps and work-hour distribution reports.Utilizing spatiotemporal database technology, it supports multi‑user trajectory overlay analysis and allows exporting reports in Excel or PDF format.

Video-Linked TrackingClicking on a person’s location automatically retrieves the nearest camera feed and supports synchronized playback of trajectory data with the video timeline.Compatible with NVRs from mainstream brands such as Hikvision and Dahua, with latency ≤ 200 ms, and supports video anonymization in privacy mode.

Workshop Staff StatisticsReal-time statistics on the number of personnel and density in each workshop, with support for overcapacity and understaffing alerts.By integrating regional electronic fences with positioning data, the error rate is ≤1%, and the access control system automatically manages area‑specific entry permissions.

Electronic fence management and controlCustomize electronic fences for high-risk areas (such as solvent storage zones and electrical distribution rooms) and visitor-restricted zones, with automatic alerts triggered upon boundary breaches.Supports polygonal and circular fence drawing, with a false alarm rate of ≤0.3%, and automatically triggers nearby cameras to retrieve footage.

Area-specific alarmRisks such as prolonged dwell time, prolonged idling, and overcapacity trigger a Level 3 alarm (audible and visual alerts, SMS, and app push notifications).Combined with a business rules engine, it supports custom alert thresholds (e.g., “solvent tank area holdup exceeding 10 minutes”).

Visitor Smart ManagementWhen registering, visitors are linked to a locator, which restricts their activity area; entering unauthorized zones triggers an automatic alert.Integrates with the OA system, enabling end-to-end digitalization of visitor appointment, approval, and access‑control processes, reducing manual management costs by 60%.

V. System Advantages

High precision and high compatibility

Bluetooth-based indoor-outdoor integrated positioning technology, with an accuracy of 3–5 meters, is compatible with metal equipment and environments subject to chemical interference, achieving an equipment online rate of ≥99.8%.

Comprehensive, all-scenario security coverage

Beacons are deployed at intervals of 30–80 meters, covering the entire plant area, and meet industrial-grade requirements such as explosion-proof, waterproof, and dustproof ratings, with a failure rate of ≤0.1%.

Deep business integration

Seamlessly integrates with COFCO Oils’ existing ERP, access control, and video surveillance systems, enabling a closed-loop workflow spanning personnel location, attendance tracking, and production scheduling.

Low-cost and easy to deploy

Bluetooth Beacons require no wiring, shorten the installation period by 70%, and reduce maintenance costs by 50%, making them ideal for rapid smart upgrades in chemical enterprises.

VI. Project Summary

The Bluetooth-based personnel positioning management system of Feixian COFCO Oils & Fats Industrial Co., Ltd. leverages integrated indoor–outdoor Bluetooth positioning technology and aligns with the safety‑management requirements of chemical enterprises, achieving a triple breakthrough: precise personnel localization, visualized production management, and intelligent emergency response. Since its deployment, the system has significantly enhanced the company’s safety‑management capabilities and production‑collaboration efficiency, offering a replicable solution for the intelligent transformation of the chemical industry and demonstrating the deep integration of technology and industrial safety management.