Centering on modeling plans and process execution standards, the system realizes data interconnection and dynamic collaboration across production links such as feeding, smelting, spheroidization, modeling and casting in the foundry workshop through functions including plan scheduling issuance, visual on-site kanban, on-site operation guidance and key production equipment data collection. This enables management at all levels to grasp production status in real time and trace back the production process.
Charging Management
Through the management of furnace charge formulas and batching calculations, and by collecting the amount of furnace charge added, economic accounting of furnace charge formulas is achieved, the one-time pass rate of chemical compositions is improved, and iron material costs are reduced.
Smelting Management
By managing electric furnace repair and sintering, and collecting data such as process parameters, energy and material consumption, quality inspection, and iron output during electric furnace smelting, the system enables accountable display of smelting costs, traceability of smelting quality, improvement of electric furnace management levels, extension of electric furnace service life, and reduction of smelting costs.
Sand Mixing Management
Through the collection of sand mixer production data, material consumption, and process data, as well as statistical analysis of sand performance indicators, the system realizes trend display and analysis of sand mixing costs, auxiliary material unit consumption, and sand performance indicators, providing a basis for management improvement and ensuring product appearance quality.
Modeling Management
By docking with modeling and casting plans, the system achieves traceability of mold information and core information. Through the collection of production information and process parameters of modeling machines, it enables statistical analysis of mold changeovers, downtime, and production efficiency, identifies anomalies, and provides a basis for management improvement, thereby enhancing production efficiency and reducing production costs.
Casting Management
By docking product, molten iron, mold, and core information, and collecting production information, process parameters, material consumption, and quality inspection data of casting machines, the system achieves traceability of product quality.
Digital Operation Intelligent Control Platform
With the help of various analysis charts, algorithmic mathematical models, and digital twin technology, the platform intuitively and vividly displays and monitors production data, quality data, equipment operation data, energy consumption, and other data, achieving real-time process monitoring, simplified production management, and convenient quality traceability. The system can also automatically push daily and monthly production operation reports to help enterprise managers reduce management difficulties and boost quality improvement, cost reduction, and efficiency enhancement.
Real-time Production Data Collection
Real-time collection of production process data from equipment ensures objective and authentic data, transparent production progress, and reduces process documentation by over 80%.
Online Production Process Monitoring
Online control of production processes with customizable early-warning indicators; real-time monitoring of indicator implementation; early detection and timely resolution of issues to minimize losses, with over 95% identification rate of production process anomalies.
Real-time Anomaly Identification and Error Prevention
Real-time identification and error prevention for anomalies in production processes, process parameters, quality information, and production efficiency to ensure the effectiveness of manufacturing execution.
Precise Product Quality Traceability
Establishing complete production data archives to achieve traceability of product quality, define quality responsibilities, and improve quality pass rates.
Steady Improvement in Production Efficiency
Multi-dimensional analysis of personnel/equipment efficiency to increase plan execution rate by over 10%; reduce downtime and line stoppage time by over 15%, and enhance production efficiency by over 10%.
Precise Daily Cost Control
Precise batching, optimal batching accounting, and cost/input-output variance analysis to continuously reduce production costs.
