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Smart Aluminum Solutions

The Smart Aluminum Factory Information Solution integrates existing systems into a unified production management platform, eliminating data silos across production units. It enables information sharing among flue gas purification, electrolysis workshops, casting workshops, power workshops, laboratories, inspection and warehousing, and production management departments—delivering end-to-end transparency, data-driven decision-making, and intelligent operations to drive aluminum plant transformation and upgrade.

Industry Pain Points

Industry pain points

Industrial enterprises are moving from traditional experience-driven operations to data- and knowledge-driven models, achieving intelligent transformation through integrated information platforms.

Low Production Efficiency

Complex production processes and low automation levels hinder productivity gains.

Inconsistent Product Quality

Outdated quality control methods make it difficult to ensure consistent product quality.

High Energy Consumption

Aluminum production is energy-intensive, leading to high operational costs and environmental impact.

Significant Safety Risks

Processes such as melting and pouring present high safety hazards.

Fragmented Management

Data sharing is limited, analytics capabilities are weak, and management practices remain siloed.

Complex Equipment Maintenance

High failure rates of critical equipment increase maintenance costs and disrupt production continuity.

Solution Objectives

Integrate and optimize information systems across all stages of aluminum production to improve efficiency, reduce costs, meet environmental standards, and minimize safety risks.

Product Architecture

Core Functional Modules

system function

Quality Inspection Management

The quality inspection data acquisition system automatically collects test data from samples (e.g., bath samples, electrolytes, finished aluminum ingots) directly from analytical instruments. Results are submitted for review, and upon approval, are integrated into weighing and batching processes. Standardized quality reports are generated for traceability and can be printed for records.

Aluminum Tapping Management

Digitizes the aluminum tapping process in electrolysis workshops, enabling real-time monitoring and recording of tapping operations. The system captures key data such as planned tapping volume, tapping formulas, tapping indications, net tapping weight per cell, start/end times, and total/net weight per lift. All data is uploaded to the unified production information platform for centralized storage and management, generating tapping reports and statistical summaries to support information sharing.

Product Inspection Management

Manages measurement of electrolytic aluminum products, including raw molten aluminum and finished ingots. Weighing data from various scales (platform scales, hanging scales) across the plant is automatically collected, and corresponding statistical reports are generated based on production requirements.

Warehouse Management

Provides digital management of aluminum ingot yards and warehouses. Through defined warehouse processes, the system tracks ingot receiving, inventory, and dispatch in real time, feeding all data to the upper-level information platform for timely, comprehensive visibility of electrolytic aluminum inventory.

Material & Procurement Management

Handles both material procurement and inventory management. Workshops and departments can select required materials by code in the procurement module and automatically generate demand plans. After approval, plans are routed to inventory management; available materials trigger picking and delivery procedures.

Equipment Inspection Management

Digitizes inspection workflows to prevent missed inspections and unclear records. The system enforces standardized, data-driven equipment spot checks. It also provides quantifiable performance metrics (e.g., inspection arrival rate, equipment integrity rate) for maintenance personnel assessment.

Digital Monitoring System

Deploys a plant-wide video surveillance system with high-definition IP cameras at key production areas, enabling comprehensive real-time online monitoring of operations.

Sales Management

Generates sales reports for finished aluminum and primary aluminum based on inspection records and warehouse transactions. Carbon block sales data is captured upon weighbridge inspection and fed back to the procurement and sales department, with statistical reports generated from system inspection records.

Scheduling Management

Establishes a centralized real-time production information monitoring system. By integrating production process status and on-site video, it achieves real-time acquisition of data from power distribution, electrolysis transport, flue gas purification, electrolytic cells, laboratories, casting workshops, weighing stations, and warehouses. All data is displayed on the integrated information management platform, providing scheduling and management personnel with accurate, real-time operational visibility to aid decision-making.

Solution Highlights

Highlights of the plan

Cost Reduction & Efficiency Gain

Reduce labor and production costs while increasing aluminum output.

Energy Saving & Emission Reduction

Real-time energy monitoring enables timely implementation of energy-saving and emission-reduction measures.

Predictive Maintenance

Equipment lifecycle management supports precise predictive maintenance, minimizing unplanned downtime.

Information Digitization

Production data is fully traceable, with multiple BI reports providing management with deep visibility into plant operations.

Data Integration

Unified platform integrates data from multiple business systems for more convenient and flexible operations.

Flexible Deployment

Supports private, hybrid, and public cloud deployment models for flexible configuration, high availability, and seamless collaboration.

Security & Stability

Robust data encryption, high concurrency handling, and high availability ensure secure and reliable operations.

Granular Management

Centralized platform enables unified management of applications, functions, and data with departmental distribution for detailed analysis and control.

Solution Value

Plan effectiveness

Enhance IT Capabilities and Product Competitiveness

Upgrade Profit Models and Lead Industry Direction

Proactive Service Reduces After-Sales Costs

Deep Data Mining Optimizes Production Processes

Reduce Production Energy Consumption

Process-Driven, Intelligent Connection with End Users

Customer Case Study

A Leading International Aluminum Producer

After a major aluminum producer deployed the Smart Aluminum Factory Information Solution, production operations and management efficiency improved significantly. The system covers key areas including bauxite supply, alumina production, electrolytic aluminum workshops, and aluminum processing, leveraging digital twins and AI algorithms to optimize processes and workflows.

Since implementation, the producer has achieved an 8% increase in alumina output, a 2% improvement in electrolytic aluminum current efficiency, a first-pass yield of over 98% for aluminum products, a 5% reduction in comprehensive energy consumption, and a 20% decrease in equipment failure rates. This digital transformation has set a new benchmark for smart manufacturing in the aluminum industry.