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For years, Suzhou Ishikawa Iron Making has adhered to a data-driven philosophy, taking the 5G digital factory as its blueprint, focusing on smart manufacturing, and continuously enhancing its competitiveness. Our Wusong River New Plant has not only introduced internationally advanced casting and processing equipment, but also integrated six major intelligent systems to establish a comprehensive smart manufacturing ecosystem, fully empowering production management and quality control.
Today, let’s explore how these six systems build a solid defense for our customers’ product quality.
01 SAP System: The "Intelligent Brain" of Enterprise Resources
System Overview
As the core of Enterprise Resource Planning (ERP), the SAP system serves as the "operations command center" of our smart factory. It precisely manages the enterprise’s core resource flows—from raw material procurement and inventory management to sales and shipment, as well as financial accounting—achieving the integration of material flow, information flow, and capital flow, and providing a stable and reliable data foundation for the entire smart manufacturing system.
Quality Assurance
Quality starts at the source. Accurate purchase, sales, and inventory data ensures rapid response to material requirements for production plans, avoiding potential quality risks caused by production interruptions or temporary substitutions due to material issues.
02 MES System: The "Commander" of Production Execution
System Overview
Qualified raw materials from the SAP system enter the workshop, where they are subject to refined production scheduling and quality tracking by the Manufacturing Execution System (MES), the "production commander."
When a quality abnormality occurs in any process, the MES immediately locks the problematic workstation and initiates a closed-loop handling process, with full traceability from abnormality reporting, root cause analysis to measure implementation.
Quality Assurance
It enables end-to-end visualized production management. If deviations occur in any process, the system automatically alarms and intercepts in a timely manner, preventing defective products from flowing to the next link and greatly improving product consistency and reliability.
03 SCADA System: The "Clairvoyant Eye" of Equipment Monitoring
System Overview
The Supervisory Control and Data Acquisition (SCADA) system collects equipment operation data in real time, providing support for equipment maintenance and process optimization.
It safeguards the operating status of key equipment 24/7. In casting production, minor fluctuations in parameters such as furnace temperature and pressure may affect product quality. Our SCADA system captures these key data in real time through sensors and triggers immediate early warnings once they exceed preset ranges.
Quality Assurance
Especially in critical links such as smelting and pouring, the SCADA system ensures that process parameters remain in optimal states, effectively avoiding product defects caused by equipment abnormalities or parameter drift.
04 Big Data System: The "Intelligent Repository" for Quality Optimization
System Overview
The Big Data Analysis System is like a "weather forecaster." It integrates supply chain data from SAP, production data from MES, and equipment data from SCADA, mines quality fluctuation rules through algorithm models, and predicts quality risks in advance. This achieves a transformation from "post-inspection" to "pre-prevention."
Quality Assurance
This "preparedness" capability shifts quality control from passive response to proactive prevention, bringing continuously improved quality stability to customers.
05 iWMS System: The "Intelligent Warehouse Management System"
System Overview
The intelligent Warehouse Management System (iWMS) fully empowers the factory’s warehousing links. Through automated data collection, intelligent scheduling, and real-time inventory monitoring, it realizes accurate and efficient management of semi-finished and finished products. The system integrates digital dashboards, significantly improving warehousing turnover efficiency, reducing costs, and enhancing benefits.
Quality Assurance
Strictly complying with quality management systems, the system supports full-process batch traceability and linkage with quality inspection data. It builds a solid data defense for quality, making warehousing a key pillar of quality control!
06 Andon System: The "Vanguard" of Problem Response
System Overview
The Andon system is a visualized real-time alarm system, acting as a "fire alarm" on the production site to eliminate quality issues at an early stage. Once an abnormality occurs at any workstation, operators can trigger an alarm immediately, and management and technical teams will respond on-site promptly.
Quality Assurance
Audio-visual alarm devices are installed at key workstations in the workshop: a red alarm indicates an urgent quality issue requiring immediate handling. This rapid response mechanism effectively prevents the generation of batch defects, acting like a "quality safety valve" installed in the production process. Problems are exposed and resolved in real time, greatly reducing the probability of large-scale quality accidents.
Synergy of Intelligent Systems: Empowering a New Era of Quality
From raw material warehousing to production execution, from equipment monitoring to warehousing management, these six systems form an all-round quality assurance network. Connected at high speed via 5G, they construct an end-to-end quality assurance system covering orders, production, monitoring, analysis, and improvement.
This system cluster transforms our quality management:From "post-inspection" to "pre-prevention,"From "experience-driven" to "data-driven,"From "passive response" to "proactive early warning."
In the future, we will continue to rely on intelligent systems,pursue continuous improvement and excellence,and provide you with higher-quality and more reliable casting products!
