Software evolution: driving aluminum's future

Innovation is a cornerstone of economic progress for any company. By fostering adaptability, innovation empowers businesses to navigate the ever-evolving landscape of production models and environmental regulations.

Intals S.p.A.

Intals S.p.A., once a modest artistic foundry situated in the heart of Milan, has evolved into a global powerhouse in the production of aluminum alloys. Operating two pioneering facilities, Intals annually produces approximately 140,000 and 60,000 tons of these multipurpose metals.

The company's unwavering commitment to innovation and environmental sustainability has resulted in the attainment of international certifications in quality (ISO 9001), environment (ISO 14001), occupational health and safety (OHSAS 18001), and energy (ISO 50001).

As Intals continues to expand its international reach and cater to increasingly specialized customer needs, it has undergone significant transformations. While celebrating its past achievements, the company maintains a forward-thinking approach, heavily investing in research and development to turn challenges into opportunities.

Sensei Team

To proactively address current needs and anticipate future developments, Sensei has assembled a cross-functional team of experts. This team, consisting of specialists in project development, management, and functional analysis, will conduct an in-depth on-site assessment of the entire production process.

By leveraging this wide range of skills, knowledge, and experiences, we aim to significantly reduce the client's workload in identifying and resolving issues. This collaborative approach will also enable us to prioritize tasks effectively, ensuring punctual implementation of any necessary updates to comply with evolving regulations.

The Developed Project

To ensure a smooth transition, we developed a step-by-step approach using a web application called "iWeb." This modular design allowed for a gradual decommissioning of the legacy management software, minimizing disruption and reducing the risk of errors.

By applying a custom approach, we were able to rapidly scale our team to include experts from different domains. This flexibility enabled us to integrate Windows applications, a communication layer with PLCs, and mobile apps as needed, tailoring the solution to the client's specific requirements.

While still under development, iWeb is already operational and covers a significant portion of the management functions. It smoothly integrates with existing software and machinery, ensuring a mild transition.

The versatility of iWeb will also make it adaptable to future needs, including new facilities.

Key features of the solution include:

• A comprehensive web application for managing and analyzing statistical data (analytics)
• A Windows application facilitating communication with industrial equipment such as scales and strapping machines (PLCs)
• A mobile app designed to streamline warehouse operations

Project Phases

Given Intals integrated operations, which embrace production, purchasing, and sales, Sensei's proposed solution is a step-by-step approach designed to minimize disruption while transitioning to the new system.

ANALYSIS

A crucial step involves gaining a deep understanding of each operational department through direct collaboration with key stakeholders.

DEVELOPMENT

Following a comprehensive understanding of the system, we meticulously evaluate the features to be retained, enhanced, or newly introduced.

Once this analysis is complete, we initiate the implementation of the iWeb system with a primary focus on a smooth synchronization with the legacy system. This dual approach is essential for two reasons:

• Contingency Planning: should any unforeseen issues arise within iWeb, users can turn back to the legacy system to preserve a steady production.
• Data Accessibility: this approach allows users to access data entered in incomplete sections, ensuring a smooth transition.

TEST

Upon conclusion of development, the entire system is deployed in a controlled test environment where end users can rigorously evaluate the new features and validate synchronization with existing processes.

RELEASE

Following a successful testing phase, the system is deployed in the production environment. Post-deployment, we provide comprehensive user support to address any unforeseen issues that may arise, ensuring a smooth transition.

Technologies

Launched in 2016, iWeb introduces innovative technologies for its era. On the frontend, we employed an MVVM pattern with the Knockout.js framework. The backend leverages the classic Entity Framework with a DB First methodology, (with a SQL Server database). The entire solution is built on the .NET Framework 4.6.2.

To facilitate data synchronization with the legacy system, we developed custom C# libraries using ODBC communication. While the desktop application aligns with iWeb's technology stack due to hardware constraints, the mobile warehouse management app was constructed using the modern Flutter framework for compatibility with Android devices.

Intals Feedback

This solution streamlines the intricate process of aluminum alloy production, including raw material procurement, chemical analysis, sampling, recipe development, sales order management, production planning, manufacturing, and global distribution. The complexity of these interconnected stages is now efficiently managed by the new system.