Taiwan's Largest Hazardous Industrial Waste Recycling Facility - TSU Utilizes IoTSuite Data Platform to Foster High-Quality Operational Decisions

Digital transformation and intelligentization have been key directions for upgrading the manufacturing industry in recent years. Taiwan Steel Union Co., Ltd., one of Asia's top three zinc resource recycling plants from electric arc furnace dust and Taiwan's largest hazardous industrial waste recycling facility, has been actively pursuing smart transformation. By implementing Advantech's WISE-IoT multi-software solutions, based on the IoTSuite data platform, the company integrates various internal operational and production data to establish a transparent and efficient management system. This initiative aims to achieve several goals, including cost reduction, quality improvement, and profit enhancement.

Implementing an Integrated Solution Based on the IoTSuite Platform

Since its establishment, Taiwan Steel Union Co., Ltd. (TSU) has specialized in the recycling and treatment of hazardous industrial waste, specifically dust collected from the electric arc furnace steel making process. Through high-temperature smelting, hazardous substances are neutralized, and crude zinc oxide products are produced and sold both domestically and to countries in Europe and Asia, contributing to resource recycling and reducing the environmental impact of steelmaking waste. In this business, the most crucial challenge is how to leverage large volumes of operational data for smart analysis to optimize processes and improve the quality and yield of zinc oxide products.

To address this, the company believes that smart technology can break down existing data silos, enabling data to flow freely create value. As a result, they decided to establish a data platform to collect information such as furnace PLC operational status and production parameters. The aim is to optimize production processes, increase zinc oxide purity, and boost profitability.

After deciding on its smart transformation strategy, the company evaluated several information technology (IT) providers and ultimately selected Advantech’s IoTSuite IoT data platform. They implemented DataInsight for heterogeneous data integration, VisualSuite for business intelligence (BI) and production performance dashboards, and Patrol Inspection for site inspections. IoTSuite serves as the foundational platform, primarily managing computing resources. DataInsight integrates IT and operational technology (OT) data to perform cross-process analysis and optimization, incorporating data from the company's ERP, PLC, lab reports, warehousing logistics, procurement, and attendance records. Through this unified data platform, they established a command center and production performance dashboard, allowing administrators to quickly detect abnormalities, notify relevant personnel to resolve issues, and help new employees understand data processing logic, preventing confusion during troubleshooting.

VisualSuite offers various visualizations, including Dashboard flat charts, SaaS Composer graphics, 3D graphics, and BI analysis charts. These tools enable personnel to monitor on-site indicators in real time, effectively capture key information, and quickly generate reports. These reports are essential for high-level decision-makers, such as the chairman, general manager, or plant manager, as they enhance management efficiency and accelerate decision-making processes.

Patrol Inspection is used to assign inspection tasks. Taiwan Steel Union Co., Ltd. has numerous pieces of equipment and facilities that require regular inspection. Previously, personnel would use paper forms to verify whether machines were operating normally. After implementing Advantech's system, all inventory and maintenance operations can now be tracked online. If any anomalies are detected, the system immediately notifies the maintenance division, ensuring quick response and strict monitoring of repair progress to prevent disruptions to production schedules.

Enhancing Management Efficiency and Quality, Reducing Downtime Probability

Overall, after implementing multiple solutions based on Advantech’s IoTSuite platform, TSU achieved three key benefits. First, they were able to quickly identify and resolve on-site issues, significantly improving operational management efficiency. Second, they established a production traceability system to monitor quality changes. This system allows for immediate review of incoming materials when quality declines, enabling timely adjustments to formulations to ensure product stability and value enhancement. Third, they introduced regular equipment maintenance, minimizing the likelihood of unexpected downtime. Even when minor incidents occur, historical records can quickly clarify responsibilities.

Given the significant benefits realized, TSU plans to further integrate additional systems and expand the application scope of the data platform, laying the foundation for future AI applications. They also intend to promote green transformation by establishing a carbon asset management system, continually enhancing their international competitiveness through the adoption of smart technology and a commitment to ESG-driven sustainability. 

• Quickly identify on-site issues and improve operational management efficiency
• Track changes in production quality and make timely adjustments to ensure quality
• Regularly monitor and maintain equipment to reduce the likelihood of unexpected downtime

The WISE-IoT multi-software solution, based on the IoTSuite data platform, enables the integration and management of industrial equipment, effectively breaking down data silos. The platform also allows for data analysis, visualization applications, and report management. The software used in this case includes:

• DataInsight for heterogeneous data integration and big data analysis
• VisualSuite for BI and production performance dashboards
• Patrol Inspection for plant inspection systems
  

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