Lianhuashan Foundry unlocks quality, efficiency and energy savings with Monitizer | DISCOVER
Driving quality, efficiency and uptime through one connected view
By partnering with Monitizer, Lianhuashan Foundry has brought every aspect of production into one clear, real-time view - unlocking greater efficiency, reducing energy costs, improving quality and increasing uptime.
Key benefits
- Real-time data across melting, molding, sand mixing, pouring and testing
- Clear, unified dashboards replacing manual data entry and siloed systems
- Improved casting quality through better process traceability
- Reduced downtime and faster troubleshooting
- Significant energy savings by analyzing consumption and shifting to off-peak hours
- Scalable cloud-based foundations for future digital optimization
“We wanted real-time data for every part of our process.”
Huludao Lianhuashan Foundry Co., Ltd has partnered with Monitizer to bring all production data into one clear view – boosting efficiency, cutting energy costs and improving casting quality.
Monitizer | DISCOVER, supported by DISA’s foundry experts, now gives the team a single digital window into every site, line and machine.
“Monitizer | DISCOVER is a very effective way to collect and display real-time data from our key on-site equipment. It gives us the information we need to improve casting quality, production efficiency and equipment uptime.” - Haotian Ren, Managing Director of Lianhuashan.
Digital tools designed for foundries
Based in Liaoning Province, China, Lianhuashan supplies 15,000 tons of high-quality, gray and ductile iron castings annually to leading domestic and global brands. With DISA vertical and horizontal molding lines, more than 150 CNC machine and a modern laboratory, the foundry continually invests in advanced automation.
Before Monitizer, teams relied heavily on manual data entry and separate data silos. The lack of a unified overview made it harder to optimize quality and track issues.
“In today's foundry industry, digital systems are essential to improve casting performance and profitability. We chose Monitizer after researching and comparing many digital solutions. Because it was developed for foundries, Monitizer has significant advantages for our molding lines and sand processing equipment.” – Haotian Ren
Quality improvement and efficient production were key goals – achievable only with real-time visibility and full process traceability.
Rapid roll-out with trusted partners
With long-term trust in DISA and its equipment, Lianhuashan moved quickly from planning to implementation. Key equipment across melting, molding and sand mixing and sand testing was rapidly connected, with data saved continuously for reporting and analysis.
“From planning through implementation and service, we have been very satisfied with both Monitizer and DISA’s professionalism and support.” – Haotian Ren
The first major milestone was establishing a cloud-hosted, centralized database for the entire foundry – a foundation for all future optimization work.
Every day, production teams monitor equipment status, sand processing behaviors and downtime causes via DISCOVER’s intuitive dashboards.
Cutting energy costs through data-driven scheduling
With large screens on the factory floor and remote access for managers, everyone now sees exactly what’s happening –in real time.
Using DISCOVER’s energy insights, Lianhuashan analyzed machine operating times and electricity consumption across the working day. That insight enabled them to shift production to cheaper off-peak times, reducing energy costs significantly.
“We can clearly see each machine’s energy consumption and adjust schedules to avoid peak electricity prices. DISCOVER also helps us solve production problems quickly and share solutions across teams.” - Haotian Ren
Weekly online meetings allow teams to share findings and solve recurring issues more quickly, suppored by newfound process transparency.
A strong digital foundation for business growth
DISCOVER now provides deep insight into the foundry’s production and plays a valuable role in customer confidence and business development.
“DISCOVER has given us deep insight into our factory's production and helps us promote our business expansion,” “Our customers know we have excellent process control and high quality standards. Seeing our digital management tools during on-site visits further increases the confidence they have in us.” - Haotian Ren
Next steps include:
- Automating data collection in melting and pouring
- Further reducing energy consumption
- Adding more fault detection and alerting
- Continuing to extend and optimize Monitizer across the factory
“The digital system acts like our eyes, allowing us to see more accurately into areas that are normally hard to reach. The Monitizer team listens carefully to our needs, responds quickly and follows up consistently.” - Haotian Ren
