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Smart Aluminum Solutions

The smart aluminum factory information solution aims to integrate the existing system, build a unified production integrated management information system platform, and eliminate the information island problem of each production unit. The plan requires all parts of flue gas purification, electrolysis workshop, casting workshop, power workshop, laboratory, inspection and warehouse, production management department and so on to share information, achieve transparency in the production process, digital management decisions, intelligent operations, and help the transformation and upgrading of aluminum factories.

Industry pain point

Industry pain points

Industrial enterprises from the traditional experience-driven to data and knowledge driven, through the knowledge base large model to achieve intelligent change.

Low Production Efficiency

The production process is cumbersome, the degree of automation is low, and the production efficiency is difficult to improve.

Poor Product Quality

Quality control means backward, product quality is difficult to guarantee.

High Energy Consumption

Aluminum production is a high energy-consuming industry with high energy consumption.

High Security Risk

In the process of aluminum production, there are high risk links such as melting and pouring, and the safety risk is high.

Management Extensive

Data sharing is difficult, analysis means are weak, and management level is difficult to improve.

Equipment Management Difficulty

The failure rate of key equipment is high, and the operation and maintenance cost is high, which affects the continuity of production.

Program Objectives

Through the integration and optimization of information systems in all aspects of aluminum production, production efficiency is improved, costs are reduced, environmental standards are met and safety risks are minimized.

Product Architecture

Core Function System

system function

Quality Inspection Management

The data acquisition system used in the quality inspection center is mainly used to collect the test data of samples such as tank samples, electrolytes, and finished aluminum ingots. The results obtained by the test analysis instrument are directly uploaded to the test data acquisition system. The laboratory technician submits the results to the auditor for review in the control. After the audit is successful, the test data will be called in the form of a report in the weighing and batching module. At the same time, the system generates a standardized test quality report for query and can be printed for record.

Aluminum Operation Management

Complete the transformation of the aluminum extraction system in the aluminum electrolysis workshop, and realize the monitoring and recording of the aluminum extraction process. The aluminum extraction system can realize the collection of the original data of the aluminum extraction operation, such as the planned amount of aluminum extraction, the formula of aluminum extraction, the indication of aluminum extraction, the net amount of aluminum extraction in a single tank, the starting time of aluminum extraction, the end time of aluminum extraction, the total weight and net weight of each lifting package, and upload these data to a unified production comprehensive information platform for unified storage and management, and generate the corresponding aluminum extraction operation report and data statistical report to realize information sharing.

Product Inspection Management

The measurement of electrolytic aluminum products is divided into two parts : the measurement of raw aluminum liquid and the measurement of finished aluminum ingot. The weighing measurement realizes the automatic collection of the measurement data of all kinds of weighing scales, platform scales and hanging scales used for weighing measurement in the production plant area, and generates the corresponding statistical reports according to the production requirements.

Warehouse Management

Aluminum ingot warehouse management Realize the information management of aluminum ingot yard and warehouse. Through the establishment of a reasonable warehouse management process, the warehousing, inventory and delivery of aluminum ingots are comprehensively tracked, and all data are transmitted to the upper information platform in real time, providing timely and comprehensive electrolytic aluminum production warehouse information for the production comprehensive information platform.

Material and Procurement Management

The material management module is mainly divided into two aspects : material procurement management and inventory management. The management process is described as follows : the workshop and department select the required materials according to the material code in the procurement module and automatically compile the demand plan. After approval, it is submitted to the inventory management module, and some materials in the inventory will start the material collection and delivery procedure.

Equipment Ispection Mnagement

This system through the electronic inspection content, the use of intelligent computer calculation, effectively avoid the occurrence of missed inspection, unclear records and other situations; To ensure the realization of the standardization, standardization and scientific management ideas of the equipment spot inspection work; In addition, the work assessment of maintenance personnel directly provides quantifiable numerical basis such as inspection arrival rate and equipment integrity rate.

Digital monitoring system

Build a company-wide video surveillance system, set up high-definition network video cameras in key parts of the production area, and implement comprehensive real-time online monitoring of the production area.

Sales Mnagement

The system generates sales reports of finished aluminum and primary aluminum according to certain formats according to the existing inspection lists and storage processing. The carbon block can be timely fed back to the purchasing and sales department after 120t weighscale inspection, and form a statistical report of carbon block sales according to the inspection sheet generated in the system.

Scheduling Mnagement

The construction of a centralized production real-time information monitoring system, through the integration of production process status and production site video information, to achieve the power supply and distribution system, electrolytic transportation and flue gas purification system, electrolytic cell, laboratory, casting workshop, jin detection, warehouse production data real-time acquisition, and the production data uploaded to the integrated information management platform for centralized display. Provide real-time and accurate scene picture for production scheduling and management personnel to assist production scheduling.

Program Hghlights

Highlights of the plan

Reduce Costs and Increase Efficiency

Reduce labor costs and production costs, and increase cement production capacity

Energy Saving and Emission Reduction

Through the system energy monitoring, energy saving and emission reduction measures are taken in time.

Preventive Maintenance

Through equipment cycle management, precise preventive maintenance of equipment can be achieved.

Information Digitizing

Production work data can be traced back to the source, and multiple BI data reports are presented, so that the management can better understand the factory.

Data Fusion

Based on the system to achieve multiple business system data, more convenient and flexible office

Flexible Deployment

Private cloud, hybrid cloud, public cloud multi-mode deployment, to achieve flexible configuration, high availability, to meet the needs of cooperative services

Security and Stability

Data encryption, impregnable, large concurrency, high availability

Detailed Management

Platform unified management, application, function, data, distribution by department, fine analysis and management

Plan Value

Plan effectiveness

Improve the level of information technology, increase product highlights

Upgrade the profit model and lead the development direction of the industry

Active service, reduce the cost of after-sales service

Deeply mine data and optimize production process flow

Reduction of production energy consumption

Process-driven, end-users to establish intelligent connection

Application Case

A large aluminum group in Yunnan

After a large aluminum group in Yunnan deployed the Zhiyi Aluminum factory information solution, the production operation and management efficiency was significantly improved. The system covers bauxite supply, alumina production, electrolytic aluminum workshop, aluminum processing and other key links, and optimizes the production process and operation process through digital twin, AI algorithm and other technologies.

Since the application of the system, the group's alumina output has increased by 8%, the electrolytic aluminum current efficiency has increased by 2%, the primary pass rate of aluminum has reached more than 98%, the comprehensive energy consumption has decreased by 5%, and the equipment failure rate has decreased by 20%. The digital transformation of enterprises has achieved remarkable results, and has become the benchmark and model of intelligent manufacturing in the industry.