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Zorc Foundry is an advanced factory process configurator designed to streamline the melting and casting of iron in the manufacturing industry.
This integrated system automates and manages the entire workflow, from preparing the melt to finishing the product, while providing real-time data and comprehensive material tracking.
With configurable BPMN processes (for each material or product, users can choose which process they need) and user-interactive tasks, Zorc Foundry enhances operational efficiency, quality control, and scalability for industrial foundries.
Foundries needed solutions for integrating and automating data across various systems to improve operational workflows. Real-time monitoring and control of processes were essential for maintaining production quality and efficiency.
Enhancing operational efficiency and reducing waste were critical goals for sustainable manufacturing practices. Accurate material tracking throughout the production cycle was necessary to ensure consistency and quality.
Additionally, offering flexibility and customization for different factory needs was vital to address the diverse requirements of foundries. Ensuring quality control and assurance at every stage of production was paramount to meet industry standards and client expectations.
The platform serves industrial foundries specializing in iron melting and casting, aiming to optimize production, improve efficiency, and strengthen quality control through automation and real-time data integration. The key markets are Germany and China.
The solution was designed to align with Germany’s precision-driven industrial standards and China’s focus on rapid innovation and scalability, ensuring adaptability to both markets’ operational expectations and technological maturity.
The client faced several significant challenges in their traditional foundry operations.
The primary issues included:
1. Complex and inflexible processes
Traditional foundry processes were rigid and could not easily adapt to different types of materials or production needs.
2. Lack of real-time data
Without real-time data, monitoring and controlling the production process were challenging, leading to inefficiencies and increased risk of errors.
3. Inefficient material tracking
The absence of an effective material tracking system resulted in poor inventory management and potential quality control issues.
4. Integration difficulties
Existing systems did not integrate well with other technologies used in the foundry, causing disruptions in workflow and data management.
5. User adoption
Employees found traditional systems difficult to use, leading to a lack of engagement and suboptimal performance.
Zorc Foundry provides an advanced, all-in-one factory process configurator designed to optimize the melting and casting workflow. Our solution addressed the client's challenges through the following features:
1. Configurable BPMN processes
We designed configurable processes that allowed the system to adapt to various production requirements and material types, providing the necessary flexibility in choosing the right process.
2. Real-time data integration
By incorporating real-time data capabilities, we enabled continuous monitoring and control of the production process, enhancing operational efficiency.
3. Comprehensive material tracking
Our solution included robust material tracking features, ensuring accurate inventory management and quality control.
4. Seamless system integration
We facilitated integration with other microservices and systems within the foundry, ensuring smooth and efficient operations.
5. User-friendly design
The interface was designed to be intuitive and easy to use, promoting better adoption and engagement among employees.
Our role in the project was comprehensive, encompassing the development and deployment of the Zorc Foundry system.We aimed to create a robust and user-friendly factory process configurator that could manage the intricate workflows of melting and casting iron.
Our responsibilities included:
1. Designing configurable foundry processes
We developed processes that could be tailored to the specific needs of each foundry, allowing for flexibility in handling different types of materials and production requirements.
2. Implementing real-time monitoring
Our team integrated real-time data capabilities to monitor the entire workflow, providing up-to-date information on the production process.
3. Material tracking and data management
We ensured that the system could track materials accurately throughout the production cycle, maintaining comprehensive records for quality control and operational efficiency.
4. System and microservices integration
We enabled seamless interaction between Zorc Foundry and other systems within the foundry, ensuring smooth operations and data flow.
5. Task orchestrator creation
We developed a task orchestrator to manage user-interactive tasks, improving operational control and efficiency.
We leveraged our expertise to create a stable system capable of handling thousands of values and measurements and interacting with other systems within the foundry.
Our knowledge of industrial automation and real-time data integration played a pivotal role in the project's success.
Zorc Foundry achieved significant milestones in operational efficiency and market penetration. Initially deployed in 2factories in China, the success led to an expansion into additional factories in Germany, now being used in more than 10 foundries.
Zorc Foundry has successfully been implemented in more than 10 foundries.
The project has led to significant improvements in operational efficiency, material tracking, and energy consumption, contributing to more sustainable production practices.
During this project, we accumulated extensive experience in developing robust solutions for complex problems and integrating multiple technologies to support the specific needs of the industry.
Our work on Zorc Foundry enhanced our ability to create scalable, efficient systems tailored to unique operational requirements.
We gained valuable insights into managing industrial workflows, real-time data integration, and quality control, which will inform our future projects and innovations.
Zorc Foundry is a web and mobile platform that functions as a factory process configurator for foundries. It automates and monitors the entire melting and casting workflow, from raw materials to finished iron products, using configurable BPMN processes, real-time data integration, and task orchestration.
Zorc Foundry is built for the metallurgy and manufacturing industries, specifically for industrial iron foundries seeking greater process control, automation, and operational efficiency.
The solution is currently deployed in over 10 industrial foundries located in Germany and China, following an initial pilot in two factories in China.
The platform addresses key challenges such as:
It enables:
