Shulou(Shulou.com)11/24 Report--

CTOnews.com, January 17, January 13, the World Economic Forum (WEF) announced the latest batch of "lighthouse factories". There are 18 new factories in the world, 8 of which are located in China. So far, the number of "lighthouse factories" in the world has reached 132, and China has 50, ranking first in the world.

The "Lighthouse Factory" project, selected by the World Economic Forum in Davos in cooperation with management consulting firm McKinsey, is known as "the most advanced factory in the world" and represents the highest level of intelligent manufacturing and digitization in the global manufacturing industry. the selection began in 2018.

The latest batch of 18 lighthouse factories: sun and Moon Semiconductor (Taiwan, China, Kaohsiung): in order to improve production efficiency and shorten delivery cycle, while dealing with increasingly complex production processes (100 process steps), the Sun and Moon Semiconductor Kaohsiung bump factory deployed multiple artificial intelligence applications in each process from inspection to scheduling, thus increasing production by 67% and reducing order delivery time by 39%.

Bosch Automotive (Bursa, Turkey): to ensure that there are sufficient investments and resources to support the production of new products, such as hydrogen components, in the future, the Bosch powertrain plant in Bursa needs further leadership in cost savings. By deploying artificial intelligence use cases such as a closed-loop process control system to prevent hydraulic erosion, and providing skills upgrading training for 100% of employees, the factory reduced unit manufacturing costs by 9% and increased the overall efficiency of equipment by 9%.

CEAT (Harrol, India): in order to increase market sales, CEAT needs to adopt greener materials and meet stringent production specifications. To this end, the plant deployed the use cases of the fourth industrial revolution, such as advanced analytical technology, to optimize the production cycle and digitize the contact points of operators, thus reducing the production cycle by 20% and reducing process waste by 46%. And reduced energy consumption by 15%. Overall, the factory increased its exports and OEM sales by two-and-a-half times in two years.

Coca-Cola (Balina, Ireland): as the company's largest concentrate production plant, the Balina plant accounts for 22% of the company's global output, providing more than 3500 minimum inventory units in 68 countries. In order to drive growth, improve resilience and solve the increasingly complex business portfolio, the factory implemented digital analysis technology use cases, reducing production costs by 16% and expanding the portfolio of minimum inventory units by 30%. And led the promotion of the fourth industrial revolution technology in the network of 17 factories.

MantaMESH (Fleur Stedt, Germany): in the highly competitive commodity market, cost advantage is a key factor for small and medium-sized enterprises to compete. For this reason, based on the technology of the fourth Industrial Revolution, MantaMESH developed an online manufacturing business model to connect customers with automated order fulfillment systems. All online transactions can be processed in real time, connecting all intelligent production plants. Through these measures, the plant increased customer activity by 261 per cent, increased production by 73 per cent, and reduced energy consumption per kilogram of products by 32 per cent.

Industrial USI (Shenzhen, China): in response to customers' demand for the rapid release of new smartphone products and to meet strict quality standards, USI has deployed 37 use cases of the fourth Industrial Revolution on a large scale. Agile product launch, rapid capacity increase and intelligent large-scale production have been achieved, reducing the time to market of new products by 29% and speeding up production capacity by 50%. The proportion of unqualified quality has been reduced by 56%, and the production cost has been reduced by 30%.

Haier (Hefei, China): with the continuous expansion of the supplier network, in order to meet the challenges of product diversity, delivery time and product quality, the factory uses a customized industrial Internet of things platform. 18 different fourth Industrial Revolution technology use cases have been deployed in the areas of supply network, research and development, manufacturing and customer service, aimed at accelerating the large-scale application of artificial intelligence, machine vision and advanced analytical technologies. In the end, the order delivery time was halved and the on-site defect rate was reduced by 33%.

Shanghai Huayi New Materials (Shanghai, China): in order to meet the challenges of 30% overcapacity and rising costs caused by market fluctuations, the company has deployed 28 advanced 4IR use cases, such as machine learning-driven process optimization and AI-driven safety management, which successfully increased labor productivity by 33%, reduced unit processing costs by 20%, reduced energy consumption by 31%, and reduced the number of safety accidents to zero.

Johnson Consumer Healthcare (Mulander, India): market demand is prone to fluctuations in a highly decentralized and complex network of dealers and suppliers. To this end, the factory deployed a number of fourth industrial revolution technologies, such as demand awareness, intelligent logistics, robots and 3D printing, reducing OTIF losses by 66 per cent, increasing time to market for new products by 33 per cent, and reducing the cost of a single product by 34 per cent.

Lenovo (Hefei, China): in order to cope with fierce market competition, serious demand fluctuations and increasing demand for customized products, the Lenovo Hefei plant, as the largest single personal computer factory in the world, deployed more than 30 flexible automation and advanced analytical technology use cases for the fourth Industrial Revolution, which increased production efficiency by 45% and reduced supplier quality problems by 55%. At the same time, it effectively manages innumerable small orders (80% of the orders are less than 5 devices).

LG Electronics (Clarksville, USA): in order to be closer to customers, LG set up a factory in the United States two years ago, but encountered a number of human resources risks and lack of production expertise. To solve these problems, LG adopted the fourth industrial revolution technology, such as deep learning, automation and digitization, and strengthened its strategic production base in the United States, increasing product sales by 68% and net profit by 703%.

Mondelez (Suzhou, China): in order to achieve the goal of quadrupling China's retail channels and doubling the number of retail stores to 4 million, and to deal with double-digit inflation caused by rising labor and logistics costs, the company invested in digital solutions for the fourth industrial revolution, transforming linear supply chains into an integrated supply ecosystem, increasing OTIF by 18%. Reduced delivery time by 32% and increased market share from 23.4% to 28.3%.

Procter & Gamble (Takasaki, Japan): in order to achieve 2-3% year-on-year growth in the end-to-end supply chain (from R & D to customers), Procter & Gamble (Takasaki, Japan) has implemented the fourth industrial revolution technology use cases, such as data flow integration, digital twinning and machine learning, reducing the innovation cycle by 72% and the downtime of trials by 21%. Increased the speed of customer order planning by 14 times.

Unilever (Indayatuba, Brazil): the Indayatuba plant is Unilever's largest detergent factory and most efficient factory in the world, but it ranks second in cost and ranks first in greenhouse gas emissions. In response to the shrinking market, the plant deployed technology use cases such as digital twinning and artificial intelligence to enhance cost advantage and operational flexibility, while minimizing environmental footprint, eventually reducing the innovation cycle by 33%, reducing production costs per ton of products by 23%, and basically eliminating greenhouse gas emissions.

Unilever (Tianjin, China): over the past three years, after experiencing the uncertainty brought to the service industry by the COVID-19 epidemic, Unilever has deployed more than 30 technology use cases of the fourth Industrial Revolution, such as a tailor-made 7-hour 24-hour digital sales model, optimized end-to-end advanced planning, and artificial intelligence-driven quality control systems, thus accelerating market penetration in low-line cities. Doubled the number of customers, reduced the order delivery time by 40%, and reduced the number of customer complaints by 62%.

Western Digital (Neihu, Philippines): in order to improve operational resilience, better respond to volcanic eruptions, typhoons, eight months of waiting for uneven quality wafers, fluctuating market demand and increasingly stringent product specifications, the Neihu plant deployed 25 technology use cases on a large scale, including the use of advanced analysis techniques to detect anomalies and the use of machine learning technology to compensate for end-to-end wafer variations. As a result, the unplanned downtime has been reduced by 82%, the output has been increased by 89.6%, and the production cost has been reduced by 54%.

Western Digital (Bombayin, Thailand): the Bambaine plant mainly produces cost-sensitive hard drives for consumer computers. In order to solve the problem of underinvestment caused by the shift of the market to solid state drives and the rising cost of materials caused by supply chain uncertainty, the plant deployed a number of fourth industrial revolution technology use cases, while reducing factory costs by 33%. Increased yield to a record 95% and reduced energy consumption by 40%.

Weituang Asset (Zhongshan, China): the pressure on the company is to deliver 60% of orders in less than 72 hours and to accelerate the end-to-end process without compromising superior quality. To this end, Wizuang Capital has deployed 33 technical use cases in the factory to change the entire value chain. Despite the problem of insufficient supply, through the adoption of the fourth industrial revolution technology, the unit human-hour capacity was increased by 32%, the defect rate was reduced by 55%, the delivery time was reduced to 48 hours, and the unit production cost was reduced by 22%.

CTOnews.com learned that Haier has added a lighthouse factory this time. So far, Haier has seven lighthouse factories, which is the enterprise with the largest number of lighthouse factories in China.

New sustainable lighthouse factory: Flextronics (Solocaba, Brazil): in order to reduce energy use, water consumption and greenhouse gas emissions, Flextronics intelligently manages factory utilities and actively promotes the development of circular economy by using Internet of things sensors to minimize e-waste in the supply chain, thereby reducing greenhouse gas emissions in areas 1 and 2 by 41%. In terms of emissions from range 3, it has successfully reduced 44 kilotons of carbon dioxide equivalent and reduced water consumption by more than 30%.

Haier (Tianjin, China): in order to improve business resilience and reduce carbon emissions in the context of rising energy costs, Haier adopted big data and artificial intelligence technology to create an equipment power load model. A production scheduling program designed to optimize energy consumption was deployed, reducing energy consumption by 35% and greenhouse gas emissions by 36%.

Siemens (Amberg, Germany): in order to achieve the 2026 carbon neutralization target four years ahead of schedule, Siemens adopted a digital process efficiency analysis and assessment tool to reduce greenhouse gas emissions from ranges 1 and 2 generated by normal production by 69%. In addition, in order to achieve decarbonization throughout the supply chain (scope 3), the factory acts as an incubator and actively develops products of the fourth industrial revolution, such as digital product passes and blockchain-based software. to facilitate the exchange of carbon dioxide data with suppliers.

The latest White Paper of the Lighthouse Factory Network: click here to see

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