Smart Factory

Data in the production site is collected in real time to be analyzed through Big Data, and optimum control is supported through AI. Through this, productivity improvement in the manufacturing industry is enabled along with quality competitive enhancement, while the management standards of facility, energy, and safety are improved to upgrade manufacturing competitiveness.

Smart Technology

  • Sensing(IoT, Connected)

    Things connected to the network through loT technology
    • Data exchange between all entities in the world such as people and things, etc.
    • Exceeding the connection of simple information to provide infrastructure for data convergence.

  • Analyze(Data-Driven)

    Analysis and prediction of future events based on Big Data
    • Hidden patterns are discovered through diverse data to create new value.
    • Linkage analysis of overall processes to discover invisible waste factors.

  • AI Control(Intelligence, Optimal)

    All system operations are optimized through Al for automatic control
    • Failure is predicted without human intervention, and an optimum operating method is established.
    • System/Facility state is predicted to optimally control the system.

  • Autonomous(3D Simulation, Interface)

    Real-time simulation and optimized autonomous operation in digital twin factory
    • Predicts design, production, quality, and logistics results with real-time simulation in a virtual space identical to the field.

Evolution Strategy

1.0 Smartize Individual Processes

Automate individual processes/equipment and make them smarter to optimize operations

2.0 Smartize the entire value chain

Optimize individual factories and expand to value chain

Future Real-time simulation and virtual verification

Create a net of autonomous, flexible factories with a hyper-connected supply chain across the company

Strategies to Drive Smart Factory
  • 01.Optimize for integrated process and inter-process penetration

    Implement integration/penetration efforts for each department

  • 02.Expand smart MES value chain

    Smartize across business areas and customers

  • 03.Expand digital twin from value chain to supply chain

    Connect collaborative ecosystems, including external supply chains

Service Area

Smart Factory Consulting, Build, Operation
Smart Factory Consulting
  • Collaboration between DX and domain experts
  • Production, quality, facilities, process logistics, ESG
  • Establish strategies in all areas from diagnosis to success
Smart Factory Build
  • Control system with edge computing
  • Leverage AI automated controls
Smart Factory Operation
  • Secure and standardize data collection system
  • Perform the entire AI modeling process
Smart Factory Consulting

After systematically diagnosing the level of the site, we establish a master plan that aligns the management strategy with the direction of the Smart Factory and provides the ideal direction.

  • Production

    We digitize the know-how of skilled workers and implement it with AI. We monitor the entire production process in real time and use AI to predict optimal operating conditions and control the operation automatically. We maximize operational efficiency by eliminating wasted time, materials, and labor throughout production.

  • Quality Control

    By linking and analyzing operation data between processes, we proactively monitor quality defects and automatically control such defects to prevent them from entering the next process.

  • Facility Management

    We utilize IoT sensors attached to major facilities in the factory to monitor the operation status in real time, diagnosing and predicting the condition of facilities and taking proactive measures for problematic facilities.

  • Process Logistics

    We implement real-time logistics tracking and visibility, and unmanned transportation systems. We take into account conditions such as raw materials, semi-finished products, products, shipments, orders, and operations to come up with the optimal route that minimizes travel time and cost.

  • ESG

    We monitor real-time carbon emissions, raw material usage, and energy bills to find the greenest production conditions. We check not only potential hazards on site, but also employee health and behavior, ensuring zero accidents even in high-risk workplaces.

Digital Twin

A digital twin is a convergence technology that creates an exact 3D model of a real-world object in a virtual space and connects it to the real world, simulating what might happen to support optimal decision-making.

  • Digital transformation of the entire factory with product/service visibility
  • Leveraging field/simulation data to streamline product design
  • Optimizing factory processes with simulation
  • Real-time monitoring and emergency response simulation
  • Improving maintenance efficiency by providing predictive information
Vision

Implement digital twin to simulate the entire process and support optimal decision-making.

  • Operation
    Operation

    Enable simulation-based autonomous operation

  • Quality
    Quality

    Pre-simulate process quality to identify defects before and after process

  • Facilities
    Facilities

    Virtual commissioning and equipment life/condition prediction

  • Safety
    Safety

    Field worker location tracking and emergency response

  • Energy/Environment
    Energy/
    Environment

    Real-time energy optimization/carbon reduction simulation

Key References
  • Smart Factory for POSCO Pohang/Gwangyang Works
  • Smart Factory for LS MnM (Formerly, LS-Nikko Copper) Onsan Site
  • Smart Factory for Pungsan Ulsan Site
  • Smart Factory for DAESUN Distilling Busan Site
  • Smart Factory for Hyosung Heavy Industries
  • Smart logistics system for Kukdo Chemical