Every year the World Economic Forum’s Global Lighthouse Network honors companies that use Industry 4.0 and Internet of Things (IoT) technologies to make their operations more efficient, environment-friendly, and lower cost. “Smart” applications have been especially valuable to manufacturers during the COVID-19 pandemic for finding ways to maintain operations and stay competitive. To date, 69 factories have been honored as “lighthouses” for leading the way in establishing smart operations that are more productive, safer for the environment, and use fewer resources.
Here are some of the smartest factories in the world:
- Alibaba (Hangzhou, China)
This fashion-and-apparel manufacturing facility utilizes cloud-based computing and IoT technologies to create an agile production system based on real-time production data. Other technology enhancements include cloud-based resourcing and cost planning, automation and robotics, and artificial intelligence (AI) to maximize quality and speed up production—for example, AI-enabled cutting machines and networked sewing equipment.
- Micron Technology (Taichung, China)
Micron’s semiconductor memory manufacturing facility utilizes an integrated IoT and analytics approach to identify manufacturing variances and provide automated root-cause analysis, which reduced unplanned downtime by 30 percent. An advanced AI-based optical inspection system analyzes millions of product images daily, which are compared to their digital twin replicas.
- Unilever (Hefei, China)
Unilever utilizes flexible automation, sensors, and cloud-based management systems across all its production, warehousing, and delivery segments, reducing order-to-delivery lead times by 50% and overall costs by 34 percent. AI is also used to create a more flexible, efficient, and transparent supply chain.
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- Saudi Aramco (Saudi Arabia)
Khurais is the largest smart oil field in the world, with over 40,000 sensors that monitor over 500 oil wells. Saudi Aramco relies on big-data analytics, AI, robotics, and digital twins to run its operations as efficiently as possible. Wells are equipped with smart downhole sensors, control valves, and pumps to monitor and adjust flow. The company also developed its own process for maximizing fuel gas efficiency in its boilers, which has reduced fuel consumption and greenhouse gas emissions.
- Schneider Electric (Lexington, Ky., U.S.)
This 60-year-old-plus manufacturing facility has totally transformed its operations with Industry 4.0 technologies. Its energy management strategy uses IoT, big data, and predictive analytics to reduce energy consumption and meet sustainability goals. Augmented reality, remote monitoring, and predictive maintenance are used to streamline operations, boost efficiency, and reduce overall costs. Digital management of its operations has reduced equipment downtime by 20 percent.
- GlaxoSmithKline (Ware, U.K.)
This pharmaceutical manufacturing facility relies on neural networks, advanced analytics, and other Industry 4.0 technologies to improve quality and streamline production. Line speeds have improved by 21 percent and OEE (overall equipment effectiveness) improved by 10%. GSK has also combined digital twins, AI, and deep-learning image recognition to detect quality defects and optimize cycle time monitoring.
- Bayer Pharmaceuticals (Garbagnate, Italy)
Bayer Pharmaceuticals utilizes machine learning, AI, big-data analytics, and digital twins to optimize the quality, efficiency, and cycle times at this facility in Italy. Augmented reality (AR) devices are also used to identify the best way to switch product lines efficiently and reduce changeover times. Process improvements are more transparent and accessible to employees on the factory floor, who get real-time updates on performance and key performance indicators, helping them make more informed decisions.