Research on the Application of New Model of Intelligent
Manufacturing in Aluminum Industry
Youfeng Li
1
and Yue Zeng
1
1
the Software Engineering Institut of Jinling Institute of Technology ,Nanjing,Jiangsu ,China,210007
Keywords: Intelligent Manufacturing; New Mode; Architecture.
Abstract: Through the analysis of the problems faced by the aluminum industry in China, the necessity of introducing
a new model of Intelligent Manufacturing in aluminum industry is put forward. Taking M aluminum
industry as an example, this paper expounds the new mode of Intelligent Manufacturing in modern
aluminum industry from several aspects, such as application goals, application difficulties, intelligent
manufacturing system architecture and architecture design ideas.
1 INTRODUCTION
With the development of lightweight transportation,
new generation of electronic information industry,
new energy vehicles, high-end equipment
manufacturing, energy saving, environmental
protection and other strategic emerging industries,
the demand for aluminum market is increasing year
by year. However, the competition of the aluminum
industry is fierce, the high-end products are few,
how to improve the comprehensive competitiveness
of the enterprises, the introduction of the new
intelligent manufacturing model is inevitable. Based
on the equipment and production line automation,
intelligent transformation of the new mode of
intelligent manufacturing, construction of
"unmanned workshop", to promote the
transformation of the mode of production to the
intelligent, flexible, fine; new type mould industry
through the establishment of industrial data analysis,
optimization and "Internet plus" collaborative
manufacturing, to enhance the research and
development, production, management, marketing
and service of the whole process of the level of
intelligence, improve labor productivity, reduce the
cost. Taking M aluminum industry as an example,
this paper expounds the construction of a new
intelligent manufacturing model for aluminum
industry.
2 PROBLEMS OF THE
ALUMINUM INDUSTRY
China's aluminum industry is developing rapidly,
but compared with the world powers, there are still
some gaps in technological innovation, industrial
structure, quality and efficiency, green development
and resource protection.
(1)The ability of technological innovation is
insufficient. Basic common key technology, deep
processing technology and applied technology
research and development are inadequate.
Aluminum products generally have poor quality
stability and high cost, and some high-end aluminum
products still rely on imports.
(2) Structural contradictions are prominent. The
concentration of aluminum industry is low, and the
strength of the enterprise is weak. The production
line of high end processing line is generally not
high, the middle and low end processing products
are homogenized and the market competition is out
of order. At the same time, with the further
standardization and development of the aluminum
processing market, the high-end products market
will gradually change to new energy materials and
functional materials such as aluminum foil for
lithium batteries, automotive aluminum and so on,
and will become a major trend of future
development.

(3) The upstream and downstream constraints are
uncontrollable. The concentration of aluminum
industry is low, and the cooperation between
upstream and downstream is insufficient, and it is
affected by the fluctuation of the upstream and
downstream industries and the operating
environment. The superposition of multivariable in
the process of production leads to the bottleneck of
the precision of the process standard for the whole
process of production.
(4) Industry transformation is difficult. The
aluminum industry has extensive production mode
and low production efficiency. It is labor intensive,
resource consumption is large and product
homogenization is serious, resulting in low
profitability. All of these restrict the development of
China's aluminum deep processing products. At
present, there is a big gap with the international
advanced production level at present. The promotion
and application of new technology, new technology
and new equipment still have a long way to go, and
the transformation of the whole industry is difficult.
In the whole industry inefficient allocation of
resources, lack of technological innovation ability
under such circumstances, China's high precision
aluminum must conform to the new round of
technological revolution and the industrial
revolution opportunities, accelerate the intelligent
manufacturing, networking, big data and other
information technology and manufacturing
integration, increase the machine substitutions and
production control applications such as efforts to
promote production change the way to intelligent,
flexible, fine; carry out the construction of public
service platform and energy control center, R & D
system, information system, operation management
system, integrated enterprise; gradually promote
industrial software, data management, engineering
services, technical standards of resource sharing and
cloud application services, the establishment of the
"new industrial model Internet plus" collaborative
manufacturing, accelerate industrial restructuring
and upgrading.
3 NEW INTELLIGENT
MANUFACTURING MODEL
3.1 New Model Application Target
The application of a new model of the intelligent
manufacturing, accelerate the intelligent plant
construction, set up production plan, process
coordination, equipment control, resource
optimization, quality control and decision support
intelligent integrated control platform to achieve
high precision aluminum production, fine, intelligent
man-machine and optimize the allocation of
resources, accelerate enterprise data sharing,
improve production and management efficiency and
promote the technology innovation continuously,
realize the enterprise management, to strengthen
industrial cooperation.
(1)Speed up data sharing
M aluminum through the introduction of a new
model of intelligent manufacturing, so in terms of
planning, scheduling, production, research and
development, business operation and market
development, to realize people and people, people
and equipment between the highly cooperative and
information group, point to the opposite point of the
real-time transmission, integration, sharing, and
small batch and large-scale production needs full
customization of M aluminum.
(2)Improving enterprise efficiency
M aluminum through the construction of
intelligent control platform, constantly optimize the
lean production mode, real-time control of material
consumption is minimized, reduce the
manufacturing process and the loss of inventory;
optimization of supply chain system, and effective
control of suppliers and customers the cost of space,
achieve both effective coordination, improve
logistics efficiency of materials and products, reduce
inventory cost three each between.
(3)Promoting continuous innovation
M aluminum manufacturing technology,
networking and cloud computing, big data, as the
representative of information technology to
accelerate the integration and innovation, the
construction of intelligent plant, promote the
automatic data acquisition system, simulation and
analysis of large enterprises to make full use of data
in real time or virtual scene, effectively activate the
innovation potential, innovation mode, efficient and
quickly respond to the market, leading the industry,
enhance the market competitiveness of enterprises.
(4) Strengthening industrial coordination
M aluminum to intelligent plant for the direction
of development, carry out the application of a new
model of intelligent manufacturing, through e-
commerce, big data, cloud platform, the response of
downstream users customization, processing and
distribution requirements, established from the early
intervention (EVI) to the full user technical support
and service system to promote win-win, service-

oriented manufacturing manufacturing, business
model innovation, improve value-added service.
3.2 New Model Application Difficulties
When the new model of intelligent manufacturing is
introduced in M aluminum industry, many
difficulties are encountered, which are mainly
embodied in several aspects.
(1)Hard hardware integration
The process of aluminum production involves
the types, quantities and interfaces of the equipment,
the complex process of the section and the great
difference in the process. It is difficult to integrate
and control the equipment of each section and
collect electronic data in an all-round way to form a
line of industrial automation. It is necessary to
cooperate fully and comprehensively with the
relevant people, things, technology and so on. In
addition, the M aluminum part of the equipment is
obsolete and needs to be replaced or modified to
provide conditions for intelligence.
(2)Difficult data acquisition and transmission
The intelligent manufacturing process requires
centralized control of the control system in all
processes to improve the industrial bus. M
aluminum industry needs to improve the intelligence
level of some energy metering instruments to ensure
the stability of data collection. It is necessary to
unify the interface modes of each machine and
equipment. It is necessary to unify the version of
every software system to ensure the coordination
between database and function, so as to ensure
unified management and protection. The internal
communication of the enterprise needs to further
improve the industrial Ethernet and achieve the
stable transmission of the data of the control system.
(3) Difficult software integration
It is difficult to integrate the intelligent
manufacturing management and control system of M
aluminum industry. It is necessary to connect with
the data and process of R & D design system,
formula system, raw material detection management
system, and need to form synergistic control with
supply chain. The need to achieve and the
production process and process standardization
management system docking, ensure the realization
of process in strict accordance with the provisions of
the file, effectively control the deviation of the
specific implementation (such as credit, price etc.),
real time tracking, contrast analysis (such as
ingredients, quality), get the corresponding results,
efficient operation, standardized management
system.
(4) Difficult data coordination
It is difficult to standardize the main data
encoding of M aluminum industry. We need to
improve the convenience of data viewing in
production process, and we need to integrate product
coding from smelting, casting rolling to packaging
process to ensure the uniqueness of product coding.
The scientific data report of M aluminum
industry is difficult. If we want to improve the
utilization rate of system reports, reduce or even
eliminate the manual processing ratio of workshop
reports, and enhance the real-time data, we should
integrate reports and unify the reporting caliber and
calculation standard, so as to make meticulous
management.
It is difficult to standardize the BOM database of
M aluminum industry. Need to use system
management tools, improve the main materials,
alloy configuration, process parameter control,
coordinate with production and business;
information tools need to establish security, establish
the BOM configuration list, according to the
authority of special control, implementation and
material consumption, intelligent workshop, supply
chain collaborative business system and job shop
Control Co.
3.3 Construction of Intelligent
Manufacturing System
(1) General architecture of intelligent manufacturing
system
Based on industry 4, intelligent plant system, key
features and core technologies, M aluminum
enterprise designs and implements a new intelligent
manufacturing mode combined with its own needs.
The overall architecture is illustrated in Figure 1.
System design in accordance with the "overall
planning and implementation of distribution"
principle, the production equipment from the
equipment intelligent, intelligent, intelligent
management, research and development of
intelligent and multi dimension data integration and
optimization analysis, based on the "Internet plus"
supply chain and industry chain interconnection,
expansion design and implementation.
The smart factory from the platform layer,
professional production level, operations control,
strategic control layer, intelligent application support
M aluminum intelligent manufacturing system to
achieve synergy, transparent management of
production preparation process, the interconnection
of intelligent equipment, intelligent manufacturing
resource management, research and production of

supply and marketing integration, intelligent
decision support. Analysis and optimization of
dynamic operation, to achieve a full range of
production process management and intelligent
control.
Figure 1: Architecture of M aluminum industry Intelligent
Manufacturing System.
Platform layer: the technology platform based on
SOA and ESB supports the construction of all stages
of the whole intelligent factory. The platform layer
includes dynamic modeling platform, application
integration platform, application development
platform, application management platform, and
cloud technology running platform.
Professional production: through digital factory
platform, the integration of equipment, control
system and production execution system is realized,
and digital factory is established to realize intelligent
control in production process. The digital factory
platform through the plant modeling tools, establish
factory digital model, through equipment integration
and data integration technology to all levels of data
integration between systems, and integrated
automation equipment, establish intelligent plant
data acquisition and monitoring; production
implementation work order planning, scheduling,
production, inspection of the whole process of
closed loop management, acquisition, production
schedule site operation, quality inspection,
production equipment state information, realize the
visualization of the production process and
traceability.
Management and control layer: to achieve
enterprise R & D, supply chain, customer
relationship, finance and other business management
and control, establish e-commerce collaborative
platform, realize supply chain upstream and
downstream synergy, ensure production, logistics,
supply and production synergy.
Intelligent application layer: through continuous
improvement and optimization technology, realize
the operation of dynamic process optimization,
manufacturing and management information
sharing, full transparent, with big data, cloud
computing enterprise intelligent management and
decision making, enhance the enterprise resource
allocation optimization, automatic operation, real-
time optimization, sophisticated and intelligent
production management the level of scientific
decision-making.
(2) The design idea of intelligent manufacturing
system
Planning and design in accordance with
industrial 4 and intelligent manufacturing elements.
From the analysis and optimization of collaborative
development of intelligent, intelligent production,
intelligent storage, intelligent supply chain system,
intelligent management, intelligent customer and
industry data, to develop and implement transparent
preparation for production in the process of
collaborative management, intelligent equipment
interoperability, resource management, intelligent
production research and production supply and
marketing integration, decision support analysis and
optimization of intelligent data, thus, to reach full
production process management and intelligent
control. M aluminum intelligent manufacturing
project implemented in three phases, MES system,
material logistics, supply chain collaborative
commerce implementation of the first phase of the
implementation of the production process,
transparency, visualization and supply chain
cooperation; research and development
management, the implementation of the second
phase of intelligent warehouse, device control,
implementation of developing and manufacturing
integration, intelligent storage management and
process control third equipment; implementation of
automatic scheduling, online optimization,
intelligent analysis of large data, intelligent
applications, big data analysis and optimization of
intelligent manufacturing.
(3)Network architecture of intelligent
manufacturing system
The M aluminum industry system uses B/S and
C/S architecture, which is mainly used in the internal

management of the enterprise. The network includes
two parts of the online LAN and the wireless LAN.
The system network architecture is shown in Figure
2.
Figure 2: Network architecture of M aluminum industry
Intelligent Manufacturing System
3.4 The Intelligent Embodiment of the
New Model
(1) Intelligent research and development
The M aluminum industry intelligent
manufacturing system can carry out new product
research and development according to the new
customer needs. The new product materials BOM,
formula, process route and production guidance are
planned. The new product is formed, from the basic
data of R & D system or PLM MES system to
transfer material definition, BOM, process route for
production, MES system planning and scheduling,
production scheduling based on P-BOM data, at the
same time in the production process of abnormal
feedback to the R & D department. The R & D
department optimizes the product formulation and
design plan, and realizes the synergy and integration
of data and process between R & D and
manufacturing, so as to shorten the product
development cycle and improve the accuracy of
production and delivery.
(2)Intelligent production
M aluminum in intelligent manufacturing
system, MES system implementation of production
plan scheduling and monitoring and scheduling,
from procurement, inventory, production and sales
to the barcode /RFID management of financial
management, the use of bar code acquisition /RFID
melting, casting, rolling, bending straightening,
cutting, slitting, thick foil annealing, cutting process
the production and packaging material input, quality
information, process parameters and production
process data, and workshop condition real-time
monitoring and adjustment, can achieve flexible
production, MES system to realize data acquisition,
error proofing, leakage alarm and process quality
control, materials, personnel, technology and other
courses, traceability. The running state of accurate
perception of enterprises, workshops, equipment,
system; execution plan decision of equipment,
workshop and production lines to make adjustments;
fast and accurate processing, recognition and
processing of real-time state data acquisition;
judgment and choice according to the results of data
analysis according to the rules set automatically
make the final. The plant state perception, precise
execution, real-time analysis, decision-making.
(3)Intelligent logistics
M aluminum intelligent manufacturing system,
the introduction of advanced barcode and wireless
communication technology in the warehouse
management, on arrival inspection and warehouse
storage, transfer, transfer bank transfer, inventory
and other each work link data acquisition
automation, ensure the accuracy and efficiency of
the warehouse management of the operation part of
data input, and can be integrated with ERP system,
ensure the real data and ERP timely and accurate
access to inventory, and maintain a reasonable
control inventory. Through scientific coding, it is
also convenient to manage the batch and shelf life of
the goods. Barcode technology WMS is a way to
achieve modern warehouse management. It is a way
to ensure warehouse operation optimization, make
full use of warehouse space, reduce operation cost,
improve agility and increase business efficiency.
(4)Intelligent management
As the core business system of the enterprise,
intelligent management is also the most basic
information system. To achieve the comprehensive
management of people, money and things, M
Aluminum Group has established a complete ERP
system based on group management and control,
including financial accounting, supply chain, human
resources, production orders, equipment
management and so on.
(5) Intelligent customer collaboration
M aluminum industry is built on the core of
CRM/MRO based customer collaboration, aiming at
building the whole life cycle management of
customers, and building a unified, complete and
cross sectoral global view of customers, so as to
achieve seamless transfer of customer information
from market, sales to customer service team.

Through the customer relationship management
system, every employee who faces customers can
get effective sales information in time and
accurately, get the information needed for high-
quality customer service, improve the core
competitiveness of enterprises, and achieve the goal
of rapid growth. The entire business process of an
enterprise, including judgment, selection, struggle,
development and maintenance, is truly customer
centered.
(6)System integration scheme
M aluminum intelligent manufacturing system,
through integration with ERP, MES, PLM, SCM and
other systems, establishes a unified data center, and
collects real-time data collected from each section
and the control system of the public system on the
smart factory platform. A monitoring platform
covering the whole company's production and
operation is established to achieve the whole process
tracking of sales orders, production process tracking,
production scheduling optimization scheduling and
product quality management traceability. Real time
collection and centralized storage of production data
are realized. To improve the enterprise's resources
allocation optimization, operation automation, real-
time online optimization, production management
refinement and the scientific level of intelligent
decision-making.
(7) Large data analysis and optimization
M aluminum industry intelligent manufacturing
system, integrated production, supply, marketing,
storage and other large industrial data, and to carry
out analysis and optimization.Based on the data
collection, data management, data analysis,
knowledge, wisdom "of the whole process of ideas
and principles, M aluminum intelligent platform,
through the establishment of a unified central data
center, a large set of material procurement, sales,
production, real-time, management, human
resources and financial data. Through the data
mining technology such as OLAP, the data is fully
excavated and analyzed. According to different
management priorities, management levels and
management dimensions, we carry out professional
analysis, performance analysis, benchmarking
analysis and problem analysis for all stages of
business, so as to identify problems, intelligent
decision analysis and promote management.
4 CONCLUSIONS
The M aluminum industry introduces a new model
of intelligent manufacturing. The core of intelligent
equipment, data acquisition, analysis automation,
system integration, "Internet plus" collaborative
manufacturing, to achieve the customer
customization B2M production mode, improve the
technical and economic benefits of enterprises,
improve the social benefits. Through the "intelligent
production equipment", "logistics and transport
material recognition accuracy", "product
development cycle", "production scheduling
accuracy", "production efficiency", "single"
productivity ", the rate of finished products",
"product defect rate", "tons of foil energy
consumption and other indicators in the comparison
system to enhance the rate before and after the
implementation of the actual proof of the superiority
is obvious, the introduction of a new model of M
aluminum, is similar to.
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