LG Smart Park, a production base of LG Electronics, has been selected as a Lighthouse Factory by the World Economic Forum (WEF). Over the past five years, LG has transformed its factory complex in Changwon, South Korea into LG Smart Park, a futuristic hub of home appliance manufacturing. The key elements of the transformation are a digitally-enabled end-to-end three-dimensional logistics system, an advanced analytics system based on edge computing technology and machine learning that predicts defects, and state-of-the-art facilities that can mass-produce multiple models to respond flexibly to customer requirements. The newly implemented “digital twin” technology enables the operation system to analyze production processes in virtual reality. It can predict if any issues will occur within the next 10 minutes and provide exact parts and materials for the assembling of each appliance with an accurate, up-to-the-minute status of the facility’s logistics operations. Sensors utilizing deep learning technology are installed throughout the factory to monitor each phase of production in real-time, helping factory workers to preemptively identify and resolve any possible issues. As a result, the cost of defective product returns dropped by 70 percent from 2020 to 2021.
Floors one, two and three at LG Smart Park employ an overhead conveyor system that quickly transports boxes containing refrigerator parts to the required production lines. Attached to each line is an intelligent warehouse that monitors inventory in real-time, enabling automated materials management, including the request of additional parts and supplies. On the ground, automated guided vehicles (AGVs) leveraging stable 5G network connectivity transport parts and materials to wherever they are needed on site. Through its three-dimensional logistics automation system, the company can minimize the amount of warehouse space needed by 30 percent compared to conventional logistics systems, and shorten the time required for hourly materials transportation by 25 percent. LG Smart Park has also adopted the use of robots featuring an AI engine and camera to make the home appliance production process faster and safer. The robots undertake dangerous and complicated tasks, such as welding and the lifting of heavy parts and equipment. LG plans to apply the innovative, smart production technologies pioneered at LG Smart Park to a total of 26 production facilities in 13 countries, accelerating the digital transformation of its global manufacturing network by 2025.