China has added 5 more lighthouse factories, bringing the total number to 42, and the demand for industrial robots is huge


Recently, the World Economic Forum announced 11 new factories to join its global lighthouse network, of which 5 Chinese factories successfully made the list, namely CATL (Yibin, China), Haier (Qingdao, China), Midea (Shunde, China), Sany Heavy Industry (Changsha, China), Western Digital (Shanghai, China).

China has added 5 more lighthouse factories, bringing the total number to 42, and the demand for industrial robots is huge

Lighthouse, known as “the most advanced factory in the world”, was jointly selected by the Davos World Economic Forum and McKinsey & Company.DigitizingManufacturing” and “Globalization 4.0” demonstrators, representing the highest level of intelligent manufacturing and digitalization in the global manufacturing field today.

The reasons for the 5 Chinese factories on the list are as follows:

CATL (Yibin, China): In order to meet expectations of substantial business growth and quality improvement and achieve sustainable development, CATL has established a large-scale green factory in Yibin City. Based on the lighthouse digital plan of CATL headquarters, the factory further applied artificial intelligence, internet of Things and flexible automation technologies, increasing the production line speed by 17%, reducing production loss by 14% and achieving zero carbon emissions.

Haier (Qingdao, China): Facing the ever-increasing demands for customized design, fast delivery and high quality, the Haier refrigerator factory has accelerated R&D, upgraded manufacturing processes and logistics scheduling models with the help of big data, digital twins and advanced visual inspection technologies. Order response cycle time was shortened by 35%, production efficiency increased by 35%, and quality performance increased by 36%.

Midea (Shunde, China): To meet the need to deliver high-quality products with shorter lead times, Midea’s Shunde plant has applied artificial intelligence, digital twins and other Fourth Industrial Revolution technologies in the end-to-end value chain, enabling 24% reduction in unit production cost, 41% reduction in delivery time, 30% reduction in R&D time, and 51% reduction in defect rate.

Sany Heavy Industry (Changsha, China): In order to cope with the cyclical fluctuations in the heavy industry market, the challenges of multi-variety and small batches (263 categories) and the production of heavy components, the Changsha factory of Sany Heavy Industry makes full use of flexible automated production, artificial intelligence and scale The IIoT has established a digital and flexible heavy equipment manufacturing system. The result was a 123% increase in factory capacity, a 98% increase in productivity, and a 29% reduction in unit manufacturing costs.

Western Digital (Shanghai, China): In response to a 250% annual growth rate, a short 18-month technology transformation cycle, and labor challenges, Western Digital’s Shanghai semiconductor back-end factory implemented diverse Fourth Industrial Revolution technologies, such as automation Product design systems, machine learning-based virtual wafer testing and intelligent planning systems. The plant reduced time to market by 40%, reduced product cost by 62%, and increased productivity by 221%.

Lighthouse Factory’s Inclusion Criteria

As the highest honor in the global manufacturing industry, the “Lighthouse Factory” is not only a medal to recognize advanced manufacturing companies, but also a goal that many manufacturing companies are striving for.

To be selected as a “Lighthouse Factory”, it is necessary to have a clear value creation for the industry.In terms of reducing manufacturing costs, improving production efficiency, and being green and sustainable, it is necessary to integrate at least 5 world-class leading technology applications, and build scalableIndustrial InternetA platform that supports large-scale replication of use cases. In addition, there is a need for a matching digital management model, talent team and corporate culture.

Specifically: First, we must focus on digital production, and gradually realize the digitization of the entire value chain from R&D, procurement, manufacturing, logistics, supply chain and customer service; second, we must achieve effective manufacturing, which can be demonstrated in key operational indicators. Excellent improvement results, such as production efficiency, energy consumption, speed to market, etc.; third, it must be replicable, and can be replicated and promoted in multiple factories to promote the transformation and upgrading of its production, management, and R&D.

Against the backdrop of a global recession, rising energy prices and supply chain disruptions, Lighthouse has become an advanced example of how to keep manufacturing competitive and sustainable, while positively impacting the economy, people’s livelihood and the environment.

Enno De Boer, global managing partner of McKinsey & Company and global head of digital manufacturing, said: “The newly selected lighthouse factory shows that in order to achieve large-scale development of the manufacturing industry, three necessary conditions need to be met. First, develop a clear strategy. Without strategic support, companies will be stuck in a pilot trap, unable to identify which technologies are important to business development. Second, employee capabilities. If employees do not have the right skills, the transformation will lose the momentum to support. Third, strong governance levels. Lack of The actual execution engine, the business can’t leverage or keep improving.”

The production efficiency of the lighthouse factory has been significantly enhanced

“Lighthouse Factory” covers intelligent manufacturing,digital transformationIt is a “synonym” of high technology content, strong innovation, high labor productivity, good economic benefits, green and low-carbon development, a pioneer model of intelligent manufacturing and digital transformation, and the “most advanced factory” in the era of intelligence. “.

In Sany Heavy Industry Beijing pile machine factory, production lines are neatly arranged, AGV automatic transporters shuttle back and forth, and the huge bodyIndustrial robotLightweight, each one is equipped with visual sensorrobotic armFlexibly dancing, assembling precision workpieces…

In Midea Group’s microwave oven factory in Shunde, Guangdong, widely used industrialrobotaccurately “control” each production step; 5G-based MES (production process management system) production kanban records and detects each production link in real time; before products leave the factory, relying on 5Gmachine visionAI (artificial intelligence), replacing traditional workers to complete product quality inspection…

In the No. 6 aluminum wheel factory of CITIC Dicastal Co., Ltd., the robot waved the mechanical arm, and the processes such as casting transfer, automatic burr milling, automatic plugging and unplugging were completed in an orderly manner. …

In these practical applications, it has also proved that the lighthouse factory has greatly improved the production efficiency. After the upgrade of Sany Heavy Industry Beijing pile machine factory, the overall production equipment operation rate has increased from 60% to nearly 90%, the production cycle has been shortened by nearly 80%, and the production efficiency and product quality have been greatly improved; relying on intelligent digital empowerment of the industrial chain, Midea The order delivery cycle of the Shunde plant of the microwave oven was shortened by 56%, the channel inventory decreased by 40%, the product quality index increased by 15%, and the internal comprehensive efficiency increased by 28%. The batch is reduced from 300 pieces to 1 piece, and one production line can produce many different styles of wheel hubs at the same time.

As of now, there are 114 lighthouse factories in the world, of which 42 are in China, accounting for more than 1/3 of the total. As more and more Chinese factories are listed on the list of global lighthouse factories, the vitality of Chinese manufacturing will attract the world’s attention.

Attachment: List of the first eight batches of lighthouse factories

China has added 5 more lighthouse factories, bringing the total number to 42, and the demand for industrial robots is huge

The Links:   68300746/DSSB-01C SH-4 ELECTRONIC


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