“DISAMATICs are famous for very high quality and uptime, but our operators were struggling to set correct moulding parameters during production,” says He Guangping, Workshop Manager at Aqua Casting. “Our new D3 had already raised our average casting quality but we saw the potential for further improvements. Our maintenance inspections were also slow, plus we only reacted to problems after they occurred, causing unplanned downtime.”
The solution? Applying and enforcing standard operating procedures (SOPs) across production and maintenance teams. To guide and support its workforce, Aqua turned to DISA and the Monitizer Platform.
The Monitizer | DISCOVER IIoT solution brings all production data together into a single database and presents it via intuitive dashboards to give Aqua’s team a clear, real-time view of its process. Monitizer | DETECT is an intelligent predictive maintenance system for foundries, designed exclusively for DISA machines.
“Monitizer is proven to perform well at other DISA sites, and is built and supported by foundry experts,” says Mr He. “DISCOVER collects and displays key parameters like sand compaction and pouring temperature in real time, guiding our operators and giving our engineers detailed process and equipment data that they can analyze to improve casting accuracy and process stability. DETECT’s automated alerting and expert remote support will increase uptime.”

Aqua’s operators now monitor live process parameters via DISCOVER to make sure their equipment is running correctly while supervisors use DISCOVER to review targets, uptime and any existing issues at the start of each shift. It’s easy for senior managers to compare production across lines, analyze historical data and report on daily, weekly and monthly performance.
“With its single, standardized dashboard view of key production metrics across teams, Monitizer supports new operators and has reduced our dependence on individual operator experience,” says Mr He.

By constantly analyzing metrics like hydraulic pressure, DETECT predicts potential maintenance issues in moulding equipment, automatically notifies maintenance teams, then recommends the best troubleshooting actions to take.
DETECT seamlessly integrates with the Monitizer platform, using the same single process database and interface. That promotes close collaboration between process and maintenance engineers, and ensures troubleshooting follows SOPs. Engineers can more easily trace root causes because the Monitizer platform links casting batches to the sand, pouring and machine health parameters that produced them.
“Early digital detection of potential failures and real-time machine performance data have helped us move from reactive to predictive maintenance,” says Mr He. “Our engineers can contact DISA’s experts within DETECT and share problem information with them to receive advice and jointly reach a solution.”

“After upgrading our foundry with Monitizer and the DISAMATIC D3, we cut 2.5% off our average scrap rate,” says Mr He. “As well as less than half the previous scrap rate[JL1] , we have less downtime and more consistent production performance with improved visibility and control. That gives us the confidence to make faster, more informed decisions.”
Aqua is continuing to expand the reach of the Monitizer platform as it turns its digital vision into reality. It will deploy more dashboards, extend data access to more roles across the foundry and apply the data it collects to support continuous improvement and standardization.
Aqua has also signed up for a comprehensive three-year DISA service support contract which includes DETECT and other specialist services such as the Total Optimisation Production Services (TOPS) program and training. TOPS features regular onsite equipment inspection and adjustment checks, plus a report on the molding machine’s condition.
“By combining DISA’s foundry expertise with Monitizer’s digital capabilities, Aqua has quickly achieved measurable improvements in quality, uptime and process consistency.” says Zhai Rusong, Senior Service Engineer at DISA. “We are delighted to continue to partner Aqua on its smart foundry journey.”
[JL1]If the customer doesn’t like this description, please just just delete this.