Case Study: Building Digital Foundations at Southern Devall

Bridging the Operational Divide

Southern Devall faced significant operational silos stemming from its history as two separate companies—Southern Towing Company and Devall Towing. In the combined organization, these divisions still primarily operate in their original respective domains (river and coastal transport), and their systems and processes remain fragmented. SD relied on a patchwork of purchased and homegrown software solutions for key functions such as maintenance, logistics and crewing, with some departments still managing critical processes manually. Without a unified system, SD struggled with inefficiencies, lack of visibility and limited access to data-driven insights.

Recognizing the need for an integrated digital solution, SD launched "Project Zulu" (which in nautical references means, “I require a tug”), aiming to consolidate its operations into a single, scalable platform with Rockwell Automation’s FactoryTalk® DataMosaix™. The goal was to enhance efficiency, improve decision-making and drive profitability by gaining real-time insights across its entire fleet and workforce.

First, we created a central hub for defining data models for Towboats, Barges, Terminals / Docks / Berths, Locks, Fleets, Waterways, Cargoes and Customers; each with detailed metrics such as a vessel’s length, air draft, number of engines and critical spares.

Then, we tackled logistics: Towboats picking up Barges, each “Trip” consisting of multiple “Voyages,” and a workflow for the logistics team to enter, track and update these orders. We added a notification system so the ship-side crew could receive, acknowledge and update their progress in real-time until a Barge had been delivered to a customer and the Trip was completed.

Next, we streamlined crew management with employee data already linked to SD’s ADP system. SD needed a better way to specify which employees were on which vessels, and when. And even if their “home” was permanently on a particular vessel, everybody has time off (“Off-Hitch”), and we need to know who is actively on the vessel at a particular time. So, we implemented a drag-and-drop tool that allowed easy and quick redefining of which ship-side employees were on which-vessels for assigning crew members to vessels, and accounting for shifts and time off.

We then digitized Coast Guard-mandated logs, replacing paper records with automated notifications and structured entry fields to ensure compliance. There are an extensive set of Coast-Guard-mandated/legally binding logs (the “Towing Vessel Record”) which had to be implemented. These requirements vary between the River and Coastal Divisions, and some logs are only entered occasionally, while others are mandated 4-times-per-day / every-6-hours-on-the-hour. We also built tools for the shore-side office for reporting incidents, tracking accidents and managing maintenance schedules – covering everything from engine checks to routine cleaning.

Beyond operations, we provided essential system-wide improvements, including SSO login, user role management and UI/UX enhancements for both function and aesthetics. SD now has an integrated platform that keeps SD’s fleet running smoothly while ensuring compliance, safety and efficiency.

Navigating Global Teams & Connectivity Constraints

With development teams in India and stakeholders in the U.S., time zone differences made real-time collaboration difficult. To stay aligned, the team implemented structured check-ins at the start and end of each development day, maintaining clear communication and accelerating decisions.

Connectivity on the water was another constraint. Most vessels rely on cellular networks, limiting real-time data transmission. While GPS tracking was successfully deployed, broader IoT integrations were scheduled for a later phase, once satellite connectivity could be established across the fleet.