In response to the production pain points of scattered multi-source data and low analysis efficiency in Baotou Hualv factory, the technical team of CERI Digital Technology Co., Ltd. carried out in-depth cooperation with on-site business personnel to investigate the business logic of the entire production process, accurately screen key data points based on the core aluminum processing technology, solve industry data problems through four core constructions, and create a new paradigm for intelligent analysis of aluminum processing. 

Build a Full Data Hub to Break Down Industry Data Islands 

The core highlight of the project is to build a high-performance data middle platform to fully break through the system data barriers such as factory ERP, MES, and equipment management. The middle platform supports the full real-time aggregation of data from multiple sources and storage forms. After standardized processing, it realizes unified storage and security control, completely eliminates the "data island" phenomenon, and realizes the real-time synchronization of production data of the entire process of the factory to the data middle platform in seconds, laying a solid data foundation for subsequent analysis and application. 

Build a Four-dimensional Traceability System to Accurately Improve Quality Control and Efficiency 

Based on the full data of casting and rolling production collected by the data middle platform, the technical team developed a data traceability module and built a four-dimensional traceability system of "time - point inspection - charging - inspection and testing", which increased the efficiency of production abnormality investigation by 90%. In the time dimension, the production details of each process node can be traced back sequentially according to the production process; point inspection tracing relies on the full process point inspection results to quickly locate abnormal process nodes; charging tracing realizes the whole process charging information traceability; inspection and testing tracing can present the distribution of full-process inspection data with composition and performance inspection and testing results as the main line. 

Intelligent Recording of Smelting Temperature Control: Process Compliance Based on Evidence  

For the core process of casting, rolling and smelting, the technical team customized and developed a melting furnace temperature measurement and recording module. The system monitors the changes in the aluminum liquid temperature curve of each smelting furnace in real time. When the temperature curve meets the effective temperature measurement conditions required by the process, it automatically records the measured temperature and duration, providing accurate data support for the post-analysis of production quality problems related to the smelting furnace temperature, and helping to optimize the process with evidence. 

Intelligent Early Warning of Process Abnormalities for Risk Prevention and Control 

The technical team has simultaneously developed a process parameter alarm module to monitor key parameter changes in real time by collecting user-configured process parameter alarm rules. When the parameter deviates from the standard threshold, the system immediately triggers an alarm and pushes it to the relevant person in charge, reducing the time interval from the occurrence to the discovery of abnormal process parameters, assisting in faster handling of abnormalities, and effectively reducing the losses caused by production abnormalities.