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Walsin Lihwa Builds a Multi-regional, Collaborative and Intelligent Manufacturing System

Walsin Lihwa, a leading wire, cable and stainless steel manufacturer with $18B annual revenue, partnered with Yonyou to build a multi-regional intelligent manufacturing system. Through the Yonyou BIP platform, the company established a Digital 3.0 architecture with unified master data management and standardized processes. The solution integrated ERP and MES systems across L3-L4 levels, enabling collaborative management across global factories. Key capabilities include automated production planning, real-time order tracking, quality integration, and transparent manufacturing processes. The implementation generated over 1,500 product feature codes and developed proprietary metallurgical standards, achieving sales-production integration and flexible multi-organizational management.

Walsin Lihwa Corporation, established in 1966 with a capital of 30 million Taiwan dollars, began by producing wire and cables. Today, Walsin Lihwa is a leading manufacturer in the wire and cable and stainless steel industries in the Greater China region. It has evolved into an international enterprise with investments spanning across commercial real estate, resources, and technology industries. Walsin Lihwa Group has an annual revenue of over 18 billion USD and ranks among the top 20 conglomerates in Taiwan, with a total workforce of approximately 50,000 employees. In 1993, Walsin Lihwa expanded into the stainless steel industry and has since developed into a globally recognized manufacturer of stainless steel products. The company produces a wide range of products, including stainless steel billets, ﬂat billets, steel ingots, cold-drawn bars, coils, seamless steel pipes, hot-rolled bars, hot/cold-rolled steel coils, and precision-rolled thin sheets. The wave of Industry 4.0 is transforming the value chains and management models of global enterprises. It requires companies not only to integrate virtual and physical operations with highly intelligent production capabilities but also to leverage advanced technologies such as big data, IoT, and cloud computing. By applying these technologies across research and development, production, sales, and service, companies can proactively and holistically reinvent their entire value chain. Building a Digital ERP Platform Through the Yonyou BIP platform, Walsin Lihwa has built a foundational application architecture for Digital 3.0, establishing standards for master data generation, standardizing application processes, and achieving unified management of master data. Based on a unified technology platform, master data and business processes (transactional data) are managed uniformly, realizing Walsin Lihwa's data governance goal of "one script, one path." In process management, Walsin Lihwa has developed a single BU process that is standardized, regulated, and unified, enabling integration and sharing of functions and resources across the group. This framework also builds a big data foundation oriented towards Industry 4.0. Throughout the system implementation, Walsin Lihwa develops a flexible, fast, and secure platform, integrating all applications to facilitate data transparency and highly efficient collaboration. It also establishes a knowledge base for sustainable operations, and enhances data optimization and data value maximization for business development. Building Intelligent Factories The five-level architecture of intelligent manufacturing, from L5 to L0, comprises the enterprise, management, operation, control, execution, and equipment levels. Walsin Lihwa' s intelligent factory development focuses on L3 and L4, aiming to establish a multi-site, layered planning system to balance sales and production demands. This framework supports a flexible production system that can respond quickly to short lead times and urgent orders. Based on factory model-driven functional design, it standardizes general workshop functions, production, and logistics management, creating an MES ecosystem for each workshop. This enables Walsin Lihwa to achieve collaborative management across multiple regions and factories worldwide. With its intelligent factories, Walsin Lihwa can: <ul class=" list-paddingleft-2" style="list-style-type: square;"> <li> Make rolling planning for three months, and forecast daily raw material needs; </li> <li> Automatic lead time estimation, enabling rough capacity assessment and preliminary scheduling during the inquiry stage; </li> <li> Generate comprehensive metallurgical standards and automate the conversion of sales orders to production orders, managing scheduling, compliant product release, and quality inspection; </li> <li> Real-time tracking of each process at L3 for sales order execution status; </li> <li> Integrate production routing with actual performance data to optimize production ﬂow and process； </li> <li> Provide detailed, real-time tracking of input, output, and efficiency for every product ID at each stage of the manufacturing process; </li> <li> Integrate production process with quality inspection, send sampling instruction and collect test results through WLCP; </li> <li> Make production process transparent. </li> </ul> As a result, Walsin Lihwa has established two major standardized systems: ERP and MES, connecting the L3 and L4 level systems. This has achieved integration between production and sales, creating a contract-centered sales-production collaboration and integrated application. To date, over 1,500 product feature codes have been generated, gradually adapting to the requirements of all order products at Walsin Lihwa. Additionally, based on Yonyou BIP' s feature attributes, Walsin Lihwa has developed its own metallurgical standards system, which guides production processes. Moreover, YonBIP' s multi-dimensional structure allows for flexible configuration and access control of HR, procurement, and sales organizations. It also enables the generation of multi-organizational, multi-perspective, and multi-layer management reports, improving overall management flexibility.

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