FAW Hongqi Wonsan Factory Digital Transformation Project
The FAW Hongqi Ulsan factory has a standard production capacity of 510,000 vehicles, covering one stamping, two welding, four painting, and two assembly workshops, totaling nine major workshops. It is responsible for the production tasks of FAW's main models and serves as an important manufacturing base supporting FAW's business development. The Ninth Mechanical Institute applied intelligent system integration solutions during the project construction, utilizing three capabilities: data collection, data storage, and data value mining to upgrade and optimize the existing systems at the Ulsan factory. New business application systems such as production management, equipment management, quality management, and energy management were established, along with intelligent application systems like APC smart energy-saving air conditioning and predictive maintenance for equipment. This achieved a system coverage rate of 100%, while integrating the new and old system architectures of the factory, focusing on breaking through system bottlenecks to ensure horizontal and vertical connectivity of systems. This promotes online and visualized business processes for production, logistics, and operations, enhancing factory production efficiency. It also enables networking of equipment across the nine workshops and adds value to production line data assets. The automatic data collection rate for key indicators has significantly improved, establishing a powerful data analysis platform that reduces equipment downtime through predictive maintenance and optimizes production parameters using algorithms to minimize quality defects. Additionally, precise control of energy consumption effectively lowers operating costs, achieving intelligent management goals of visible data, lean production, predictive equipment maintenance, and controllable energy consumption. This has greatly reduced factory operating costs and significantly improved production operation efficiency while greatly enhancing product qualification rates.
This achievement of integrating new and old system architectures and deeply promoting intelligent transformation not only reshaped the production model of the Ulsan factory but also set a benchmark case for transformation and upgrading in the entire industry.
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