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【2021 Application Example】 AI Complements the Disruption of Traditional Industry Experience: Production Forecast Analysis in Plastic Recycling Process

As the number of veteran craftsmen in traditional industries diminishes

In Taiwan, SMEs have always played a central role in Taiwan's industry, accompanying Taiwan through various 'economic miracles' periods. But as time progresses, the old masters gradually became elderly craftsmen. Coupled with the phenomenon of fewer children and changes in the overall industrial structure, fewer and fewer of the new generation are willing to enter traditional industries. Now, it can be observed that the main combination on most SMEs' operational fields is formed by 'elder craftsmen' together with 'foreign workers.' These experienced craftsmen, who act as living dictionaries of field experience, suffer from a lack of successors to continue the tradition, leading to a growing difficulty in sustaining on-site experience transfer in traditional industries.

The limits of traditional hands-on process optimization are in sight

Located in Tainan Baoan Industrial District, 'Tangxian Company' was established in 1972, initially manufacturing high-quality weaving equipment. It possesses the capability to manufacture machinery, and in recent years it has actively developed environmentally friendly plastic recycling equipment in response to international green energy, recycling, and environmental protection demands. Ultimately, they have successfully developed low energy consumption, low waste, high purity, and high output recycling granulators with a sleek and efficient machine design supplemented by advanced intelligent control technology.

▲Tangxian Company's self-developed plastic recycling granulator equipment

However, in the production process of plastic recycling, when faced with hundreds of material types and dozens of process temperatures, speed settings, what is faced is thousands of possible parameter combinations. Previously, the adjustment of various production process conditions was reliant on the on-site staff (the experience of the craftsmen). Thus, during the transition of production of different incoming materials (such as PET, PP, PE), a significant amount of raw materials would be wasted during the trial phase.

The professional information gap in traditional industries

Tangxian Company recognizes the importance of data. In the past, although process parameters were recorded, due to a lack of data capabilities at the time, it was primarily in paper form, manually written down by the operating staff, accumulating a large amount of paper data. However, this also meant a lack of scientifically accurate and detailed information available for real-time reference and adjustment.

Process parameters logbook, records the state of about a dozen machines and production figures hourly

▲Process parameters logbook, records the state of about a dozen machines and production figures hourly

In quality control as well, due to a lack of control over the quality of output and monitoring and feedback mechanisms for unit time production, it becomes difficult to predict the profit conditions of each batch. Production management can only estimate and average cost and productivity changes over the process from the outcomes, without being able to objectively and timely restore the production conditions to reasonableness or make clearer adjustments when facing quality abnormalities.

Site reality (left image shows recycled scraps; right image shows pellet production)

▲Site reality (left image shows recycled scraps; right image shows pellet production)

Taiwanese manufacturers possess strong machinery manufacturing capabilities, and many modern machines now have data capabilities, recording real-time status and information via IoT. But is the infrastructure of the factory's on-site and information systems ready yet?

When the Old Master Meets AI

With government referral, Tangxian Company partnered with a Taiwanese data science company, working together to integrate AI services and optimize internal processes using AI. They started with a medium-sized plastic recycling production line within the factory as a trial field. After establishing a successful benchmark, this model was expanded to larger plastic recycling machinery within the factory to continue verification and application.

Initially, both parties converted the past handwritten paper data into digital format using OCR supplemented by manual correction. Tangxian Company also worked with the supplier of the human-machine interface of the machinery to integrate the control panel and parameter data into the factory's database, allowing real-time monitoring of machine status and eliminating the complexities and potential errors of manual transcription.

Panel of plastic recycling granulation machine, showing current process temperatures, speeds, and power usage

▲Panel of plastic recycling granulation machine, showing current process temperatures, speeds, and power usage

Meanwhile, the Taiwanese data science company further modeled dozens of parameter data through AI, conducting scenario analysis to simulate various production possibilities under environmental parameters and material inputs, identifying key characteristic parameters and providing parameter adjustment recommendations to decrease costs during the trial phase.

Applying data analysis to traditional industry machinery processes

▲Applying data analysis to traditional industry machinery processes

After the old master receives the raw materials, they only need to enter the relevant material characteristic parameters, and the system automatically generates recommended process parameters. After small adjustments by the old master, they proceed with the trial production of the material, effectively reducing the waste of materials, water, electricity, and manpower caused by incorrect attempts. Moreover, Tangxian Company has proactively deployed the concept of 'production pedigree' in the plastic recycling process, allowing the batch's raw materials and process parameters to be accessed by scanning a QRCode.

Production and sales pedigree of plastic recycling pelletizing

▲Production and sales pedigree of plastic recycling pelletizing

Taiwan's SMEs have strong machinery capabilities, just waiting for the 'east wind' of data

From industrial revolutions 2.0 to 3.0, even 4.0, many Taiwanese SMEs face challenges in transitions not just in upgrading machinery, but after investing in modern equipment and generating data, they do not know how to utilize it effectively. It is impractical for these manufacturers to develop a specialized data analysis department on their own; meanwhile, Taiwan also has many innovative teams with strong software capabilities in AI and data analysis, possessing the technology but lacking the field and data. Therefore, if the traditional industries of Taiwan could be fully integrated with the innovative teams in AI and data analysis, it would not only address the current challenges of manpower and experience transfer faced by traditional industries but also advance Taiwan's development and application of AI significantly.

「Translated content is generated by ChatGPT and is for reference only. Translation date:2024-05-19」

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[2023 Case Study] AI Steps into Philanthropy: Stylish Tech at Food Banks

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turnover rate This highlights the challenge of scaling up food bank services while lacking corresponding labor and material management systems At the same time, food bank resources come from various donations, thus they vary greatly in type, shelf life, standards, and quantity Volunteers at mini food banks, mostly also elderly, must handle multiple responsibilities such as case services, food resource management,resource allocation, and resource development Sometimes they must also explain and accept immediate, large quantities of specific resources, such as adults receiving baby formula 'Food Bank-Warehouse and Transportation Center' Resource Inventory Relies Entirely on Manual Labor Mini Food Bank Volunteers Handle Multiple Responsibilities Photo Source Taiwan Food Bank Association Reducing Scrap Resources60 Increasing Speed of Resource Transfer80 To enhance resource management and ensure effective use of materials, and to address personnel shortages, this field validation case has 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reinforcement learning constructs the management mechanism for the food bank's warehouse, perfecting the classification of donated goodsRNNTechnical construction of classification models further use of reinforcement learning constructs food bank warehouse management mechanisms, making the classification of donated goods perfectlike white rice, instant drinks, noodles, instant noodles, and canned goodscan then be automatically assigned storage based on storage assignment principles AI Service System Process and Description Source Taiwan Food Bank Association AtAIUnder forecasts, it can optimize the speed of resource transfer and allocation, effectively and accurately match resource donations reducing the loss in the donation process, increase the accuracy of resource distribution, and improve the service rate—the successful donation rate—reducing the waste of resources due to incorrect items, and enabling instant monitoring of food resource stock, ensuring operators can respond quickly 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【解決方案】搭上綠能商機 華鉬實業打造全釩液流電池儲能系統設備 長效儲能的最佳選擇
Taking advantage of green energy business opportunities, Hua Molybdenum Industry creates all-vanadium redox flow battery energy storage system equipment, the best choice for long-term energy storage

Green energy is the future trend and will surely lead to huge business opportunities in the future Wind power has been one of the green energy sources that have attracted global attention in recent years It will become an important force in my country's renewable energy and help Taiwan's power generation reach the goal of 20 by 2025 to improve Taiwan's energy independence As the number and power of domestic wind turbines wind turbines increases year by year, it is particularly important to ensure that the power storage equipment achieves safe, long-term performance, is not easily attenuated during charging and discharging, and is sustainable, low-carbon and environmentally friendly At the same time, the wind turbine equipment itself Health inspection, maintenance and repair have also become the focus of wind farm operators In order to meet the needs of wind farm customers, the green energy business unit of Hua Mo Industry has launched long-lasting energy storage all-vanadium redox flow battery electrolyte and wind turbine AI predictive operation and maintenance, providing 100 safety, long-term efficiency and reducing customer initial manufacturing costs cost-effective power energy storage equipment, and through AI predictive operation and maintenance services to help customers reduce power generation costs by 10 and save up to 30 in maintenance and warranty costs Hua Molybdenum Industry was established in 1998 The industry started by refining vanadium, molybdenum and rare metal elements and other products, and used them in high-end steel, professional chemicals and specialty chemicals industries, and vanadium is more like a steel-making Vitamins can increase the effectiveness of steelmaking Among them, vanadium and molybdenum related products are one of the company's main projects The company sees that the all-vanadium redox flow battery, which is 100 vanadium-based, will be a very promising mainstream green energy technology in terms of long-term energy storage in 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consumption is mainly between 4 pm and 10 pm, which is the peak period for people's daily electricity consumption For this reason, the Energy Administration specifically requires Taipower to strengthen the upgrade of energy storage equipment, which has also driven the market's interest in all-vanadium redox flow batteries Energy storage system equipment is in high demand In addition, Taiwan's current total power reserve construction and contribution has not yet reached 100MW, and the gap from the 2025 target of 15GW of power storage is still more than 15 times Using all-vanadium redox flow batteries to successfully create 100 safe, low-carbon, environmentally friendly and long-lasting energy storage system equipment Compared with the short-term power storage of lithium batteries, the biggest advantage of all-vanadium redox flow batteries is that it is globally recognized as a long-term power reserve It can store energy for a long time up to 12 hours, which means that if it is charged 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turbines uses machine learning The main technology provider comes from ONYX Insight, a subsidiary of British Petroleum BP The company uses AI Hub analysis software technology to analyze the wind turbines faced by Taipower Pain point analysis, including power generation loss of road-based wind turbines and damage prediction of key components of land-based wind turbines such as gearboxes, pitch bearings under abnormal vibration three-dimensional vibration frequency or abnormal temperature, etc output Through this implementation, it can effectively help Taipower reduce power generation costs by 10, increase asset value by 12, and save up to 30 in maintenance and warranty costs In the past three years, ONYX Insight has successfully predicted and operated more than 20,000 offshore or onshore wind turbines around the world, accumulating extremely high AI model accuracy It is believed that the international partnership established with ONYX Insight will effectively guide and accelerate the green energy division of Hua Molybdenum Industry in its goal and layout to become an independent technology service provider for wind turbine AI predictive operation and maintenance Works with partner ONYX insight to provide customers with an AI predictive operation and maintenance system, including wind turbine power generation loss and damage prediction of key wind turbine components Building a solid foundation for domestic wind turbine operation and maintenance, using Taiwan as a base to expand to Southeast Asian wind farms The market output value of offshore wind turbine AI predictive operation and maintenance in Taiwan will exceed NT30 billion in the future, and the energy storage market has an output value of more than 100 billion US dollars globally In the future company vision, Hua Molybdenum Industrial hopes to become An independent technical service provider for vanadium flow battery electrolyte and wind turbine AI predictive operation and maintenance The long-term goal is to establish a local supply chain of vanadium flow battery electrolytes around the world by accumulating abundant technology and performance capital to supply industry needs nearby 「Translated content is generated by ChatGPT and is for reference only Translation date:2024-05-19」

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Realizing the dream of unmanned stores, Magpie Life is building the future of the smartphone industry

"The DNA of Magpie Life is not limited to vending machines We believe that vending machines combine technology, access, and humanities to bring us exciting results" This is a sentence on the official website of Magpie Life Let the vending machines bring To live a pleasant life and build a considerate, technological and sustainable future for the smartphone industry is also the original intention of Magpie Life Founded in 2018, Magpie Life launched Taiwan’s first private-brand mobile payment scan code sensor 4 months after its establishment, completing the consumption experience through screen touch The Magpie U1 smart vending machine manages the POS system and gathers data in the background, allowing consumers to synchronize with the world's new retail pace and experience a new retail consumption experience of purchasing convenience, checkout security, visual entertainment, and improved logistics replenishment efficiency Traditional vending machines lack information visibility and AI 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vending machines are less flexible and cannot adapt to changes in consumer preferences Traditional vending machines have shortcomings such as limited change shopping, single payment tools, limited number of products, and few choices Affected by the COVID-19 epidemic, consumption habits have shifted to contactless methods, causing the unmanned store market to heat up Generally, vending machines can only place relatively simple products such as drinks, food, etc The properties available for sale are limited The patented vending machine developed by Magpie can adjust the shelf space and is equipped with a lifting cargo elevator, which is suitable for various types of goods In addition, the machine is equipped with an industrial computer and a large-size touch display screen, which can meet the needs of advertising support at the same time It is expected to move towards a storeless store According to Magpie Life Observation, the consumer market trend in the past two years is that consumers demand convenient life, food consumption patterns value dining experiencesimple and fast, and are equipped with mobile phone-connected ordering models, and hot drinks and Fresh food delivery is the focus of two major trends The location, items sold, consumption methods and multiple payment methods are the focus of market growth for smart vending machines In terms of convenience, Taiwanese consumers still prefer to purchase vending machine food near stations, airports, schools, and businesses in business districts Various payment methods are also gaining more support from consumers, indicating that in the future, automatic Vending machines can be developed in two directions diversified items and diversified payment methods AI sales forecast technology integrates back-end management to achieve precise marketing purposesDue to the wide variety of products, it is difficult to know the performance of products under different factors such as season, market conditions , promotional activities, etc, it is easy to cause out-of-stock or over-inventory situations Magpie Life has specially developed "AI sales forecasting technology" and integrated it into the back-end management system, hoping to lock in customer purchasing preferences and intentions through data analysis In order to achieve the purpose of precise marketing, make accurate business decisions and effectively allocate limited resources The introduction of AI systems can achieve the three major goals of precise marketing, inventory management and supply chain management This system is a replenishment decision-making aid designed specifically for supply chain managers It uses AI to predict future sales demand, helping companies effectively optimize production capacity, inventory and distribution strategies Its overall system architecture includes1 Data exploratory analysis function Provides automatic value filling, automatic coding and automatic feature screening functions for missing values in the data 2 Modeling function 1 Provides model training functions for two types of prediction problems regression Regression and time series Time Series Forecast nbsp2 Supports Auto ML automatic modeling, and the best model is recommended by the system Integrated models can also be established to improve model accuracy nbsp3 Supports multiple algorithm types Random Forest, XGBoost, GBM and other algorithms nbsp4 Supports a variety of time series models exponential smoothing, ARIMA, ARIMAX, intermittent demand, dynamic multiple regression and other models nbsp5 Supports a variety of model evaluation indicators R, MAE, MSE, RMSE, Deviance, AUC, Lift top 1, Misclassification and other indicators nbsp6 Supports automatic cutting of training data sets and Holdout verification data sets, and can manually adjust the ratio nbsp7 Supports automatic model ensemble learning Stacked Ensemble, balancing function learning Balancing Classes, and Early Stopping nbsp8 Supports the creation of multiple models at the same time The system will allocate resources according to modeling needs, so that modeling, prediction and other tasks have independent computing resources and do not affect each other In the overall server space With an upper limit, computing resources can be used efficiently nbsp9 It has in-memory computing function, which can use large-capacity and high-speed memory to perform calculations to avoid reading and writing a large number of files from the hard disk and improve computing performance 3 Data concatenation function Using API grafting and complete data concatenation automation, there is no need to manually import data, improving user experience 4 Chart analysis function Provides visual charts and basic statistical values for product sales AI data analysis solutions have two major advantages 1 Entrepreneurship machines can be rented and sold at low cost to open unmanned physical stores and cooperate with the chain retail industry Through smart machines, entrepreneurs can rent and sell them at a lower cost than the store rent Cost of running a retail business Two cooperation models, machine sales and leasing, are provided, and the choice is based on the evaluation of the industry 2 Various types of products are put on the shelves Products are sold anytime and anywhere 24 hours a day Up to 60 kinds of diversified products can be put on the shelves Large transparent windows enhance the visibility of products Regular replenishment and tracking of product sales status are available, and product types can be adjusted according to needs Recently, the line between the Internet and the physical world has blurred, the way customers interact has changed significantly, and consumer demand is changing and personalized The retail industry is facing unprecedented challenges and uncertainties, and mastering data has become key AI data analysis solutions can help the retail industry quickly activate large amounts of data, create seamless personalized experiences, optimize the operational value chain and improve efficiency, and strengthen the core competitiveness of enterprises 「Translated content is generated by ChatGPT and is for reference only Translation date:2024-05-19」