The G division of LS Industrial Systems’ (IS) Chengju production represents one of the most advanced “smart” production facilities in Korea. With all production lines automated – from parts supply to assembling, testing and packaging – the Chengju plant represents the domestic heart of smart factory innovations.
The G division specializes in the production of low-voltage circuit breakers and magnetic switches. The production lines of low voltage circuit breakers, which are located on the first floor, annually produce 2,600 million industrial breakers. The supply of material is designed to be maintained for a day and a half of use.
All production lines in the Chengju production center are equipped with Programmable Logic Controllers (PLCs). Acting as an alternative to switch boxes, PLCs are connected to PCs and the Manufacturing Execution System (MES). PCs, on the other hand, serve a higher level role in the scope of the machine, conducting complex calculations, monitoring, measuring, and networking the factory together. A MES is a cloud-based execution solution that serves to configure the network between each plant and the host system and orchestrates real-time production management and inventory control.
Along the passage between production lines are blue markers or magnetic guide tape. Automatic guided vehicles (AGVs), or mobile robots, carry finished goods via the markers or wires in the floor.
The AGVs execute programmed instructions and move finished products to the packaging line. When a physical force is exerted on the robot, it stops, makes loud beeping noises and flashes its lights.
The packaging line is also fully automated. Weight sensors ensure accurate weight reads. Large packaging robots package items at regular interval by product type and size. The automated line takes the nameplate from Enterprise resource planning (ERP), and automatically attach to the box. ERP is management software that facilitates stock and inventory tracking
The assembly system for the magnetic switch is located on the 2nd floor of the G division. Annually producing 1,200 million switches, facilities on the second floor feature complete smart production lines. Apart from winding coils, the production lines handle testing and loading.
Through the monitor, the operator on the assembly line can check the data retrieved from the PLC installed every corner. The data collected in real time is used to improve productivity via MES. With every production line generating an average 50 million pieces of data each day, the information collected throughout the entire plant contributes to improving the company’s “Big data” system.
Each unit also undergoes quality control tests by inspection robots that produce strobe lighting. The process improves quality control, as its bright light can detect fine details.
Namely, strobe lighting serves to minimize the difference in finding errors by the human eye. Together with a vibration sensor that can quantify the noises created by a magnet switch, the final process at the Chengju plant contributes to upgrading the quality of the whole manufacturing process. After finishing the entire inspection, AGB carries the finished products to packaging lines and packaging robots carry out a series of final packaging processes.
The LSIS Cheongju Smart Plant is powered by an Advanced Planning System (APS). Referred to as a demand forecast system, an APS optimally allocates raw material and produces to meet demand. An APS also allows flexibility throughout the entire manufacturing process, from production planning to material ordering, assembling, testing, and packaging, while delivering unprecedented levels of scheduling accuracy and efficiency.
The LSIS Chengju plant has been built in stages since 2010. By incrementally adopting advanced ICT and automation, the Chengju plant has realized a mass production system that can produce diverse products and achieve customization and small quantity batch production.
The wait time has been cut in half and productivity has been improved by 60 percent. As for low voltage circuit breaker, the productivity of 38 items per day has increased to 7,500 and then to 20,000. The number of product defects have also decreased to 8 parts per million (PPM).
Efficiency has also greatly been improved. Energy usage has been cut down by 60 percent. Labor for each production line is cut in half, and surplus labor is relocated to a new business line.Experts evaluate the LSIS Chengju production center to be somewhere between Intermediate 1 and Intermediate 2 stages out of 5 developmental stages, and domestically recognized as a technologically excellent case.
To this end, LSIS continues to adopt CPS, IoT, and Internet of Service (IoS)
technologies in addition to solution. Moreover, the LSIS will continue to train internal specialists by providing technical training and organizing capacity-building field trips.
An LSIS insider said, “Productivity and energy efficiency are greatly improved through the adoption of smart production lines. Moreover, the new system turned out not only to enhnace customer satisfaction but also improve the working environment.” He added, “LSIS will continue to upgrade the current system and contribute to bringing more innovation to the manufacturing industry in Korea.”