As China enters the 14th Five-Year Plan new development cycle, boosted by the wave of digital technology development such as 5G, big data, and artificial intelligence, more manufacturing companies have more urgent needs for digital transformation, and a global COVID-19 epidemic has brought severe challenges to the majority of enterprises, while also improving the ability of digitalization to be sustainable and earthquake-resistant, and putting forward new requirements for enterprise management, R&D management and supply chain guarantee. At the same time, we have also seen that the industry pioneers who have taken the lead in practicing digital transformation have performed well in resisting the COVID-19 epidemic and supply chain oscillations, which not only further opens up the gap between them and their followers, but also becomes an industry beacon, but also provides a benchmarking guide for the digital transformation of more latecomers.
On October 27th, Industrial Fulian, which has successfully built a number of lighthouse factories, joined hands with the e-works Research Institute, a research think tank that has deeply cultivated the field of intelligent manufacturing, and the newly promoted lighthouse member CITIC Dicastal Group, jointly held an online conference to officially release the 2021 "Lighthouse Factory Leads the Digital Transformation of manufacturing Industry" white paper, and invited industry experts, lighthouse builders and other big coffee to gain insight into the global digital trend, present the "secret" of the construction of 90 lighthouse factories around the world in multiple dimensions, and deeply unite electronics, automobiles and medicine for the first time Residential and home furnishing and other representative industries and successful lighthouse enterprises deeply display digital construction examples, help enterprises understand the value of lighthouses and build lighthouse-type factories, and provide practical guidance for digital transformation.
White paper "Lighthouse Factory Leads the Digital Transformation of Manufacturing"
As Professor Li Jie, Vice Chairman of Hon Hai Technology Group, wrote in the foreword of the white paper, the reason why the "Lighthouse Network" project has become increasingly influential is that its value orientation pays more attention to the business value brought by the upgrading of business systems and the application of innovative technologies, emphasizes the cultural and organizational ability support of full participation of enterprises, and the improvement in the customer-centric end-to-end value chain, and values the "reference value" in the enterprise transformation story.
< h1 toutiao-origin="h2" > insight into the future, the lighthouse factory has become a new benchmark for construction</h1>
The Lighthouse Network is a global "Lighthouse Factory" project launched by the World Economic Forum (WEF) and McKinsey & Company in 2018 to find digital transformation models in manufacturing and summarize the approach paths behind these best practices, making them a vivid and detailed transformation story for other manufacturing companies to refer to. In the past three years, 90 factories from many countries and different industries around the world have been selected as "lighthouse factories", and China alone occupies 31.
Global "lighthouse factories" are geographically distributed
At the same time, McKinsey also found that in the process of promoting digital transformation, more than 70% of enterprises are still in the "pilot dilemma". And in the next 5 years, more than 57% of enterprises will build new digital/smart factories as the transformation path of key construction, and more than 45% of enterprises will invest more than 100 million yuan in smart factory construction. This means that smart factories have become the hub and core of China's manufacturing transformation, and more and more enterprises are moving from the introduction of single technologies in the past to the overall digital transformation, which is more urgent for the benchmarking role of the lighthouse and the value of breaking through the "pilot trap".
Key points in the construction of enterprise digital/intelligent transformation (source: e-works)
With the large-scale adoption of new technologies, innovative business processes, management systems and industrial Internet, data systems, etc., as well as the formation of rapid response to market demand, innovative operation and maintenance mode, green sustainable development of the new form, lighthouse factory enterprises can break through the limitations of cost reduction and efficiency improvement in terms of production efficiency, agility, new product listing speed, customization and sustainable development, and become the "new goal" of China's manufacturing enterprises, effectively helping enterprises to create benchmarks and break through the "pilot trap". Its value has also been recognized by more enterprises.
<h1 toutiao-origin="h2" > go deep into lighthouse enterprises and unlock digital transformation</h1>
Through an in-depth analysis of the 90 lighthouse factories and 124 lighthouse use cases, the white paper points out that enterprise transformation is not limited by industry and geography, and that manufacturing companies in various industries have the potential and opportunity to achieve their lighthouse goals. Some only focus on manufacturing itself, more focus on opening up the end-to-end value chain, and at the same time, under the concept of green development, lighthouse factory enterprises are also actively using new technologies to cope with the challenge of climate change, reduce carbon emissions and waste of resources, and enhance sustainable development capabilities.
Lighthouse Factory use case
Among them, Foxconn, Procter & Gamble, Schneider Electric, Renault, Johnson & Johnson and other nearly 1/3 of the enterprises have a number of lighthouse factories, which not only once again proves the value of lighthouse factories to break through the pilot trap, but also shows that the scale of gradually rolling out from a single lighthouse factory construction pilot to multiple factories is very successful. Professor Li Jie attributed this to "their successful use of digital technology to optimize business processes, change the way employees in the production department work and the form of collaboration in the end-to-end value chain, and achieve a systematic transformation of the operating model".
<h1 toutiao-origin="h2" > light up the "lighthouse" and tailor the transformation path of Chinese manufacturing enterprises</h1>
When the large-scale value of the lighthouse factory is revealed, it becomes an urgent need to help more enterprises light up the "lighthouse". The white paper also gives a systematic methodology of "three major grasps" and "two basic points".
The three major grasps and two basic points constitute the core elements of the transformation and upgrading of China's manufacturing industry
That is, driven by customer needs, industrial policies, competitive environment, and disruptive technologies, we should first clarify the strategic vision of the enterprise, firmly grasp the construction of an excellent manufacturing system, open up the end-to-end value chain, innovate the "three major grasps" of business models, and focus on building the two transformation foundations of digital capabilities and organizational capabilities. Further landing in thousands of industries, the white paper gives a specific implementation path according to the product characteristics of enterprises in different industries and the location of the industrial chain.
Three gripper lighthouse implementation paths
For example, in the electronic manufacturing, steel, chemical and other industries as the representative of the "excellent manufacturing" type of enterprises, they face corporate customers, the degree of product homogenization is high, the price competition is fierce, so it is recommended to optimize the manufacturing system along the main line of lean, automation, digitalization, and intelligence to achieve the ultimate cost reduction and efficiency. For enterprises that open up the end-to-end value chain with the orientation of "all-scenario customer value", we pay attention to the dynamic optimization of the whole life cycle of the order on the order side to achieve accurate planning, flexible production and rapid distribution, and on the product side, we emphasize agile research and development, product quality assurance and continuous aftermarket services through product life cycle management. For enterprises that take the "innovative business model" as an opportunity to innovate their business models, it is necessary to form an ecological collaboration model based on C-end consumers.
In addition, enterprises also need to consider digital application deployment in the process of digitalization, build a unified data governance system, multi-level collaborative industrial Internet architecture, cloud-serviced system platform and intelligent manufacturing, and design a more flat and agile digital organization from multiple dimensions of corporate culture, architecture, personnel and processes.
<h1 toutiao-origin="h2" > from the lighthouse factory - lighthouse enterprise - industrial cluster, amplify the scale value of the lighthouse factory</h1>
When talking about the value of enterprise scale, Liu Zongchang, vice president and chief data officer of Industrial Fulian, pointed out in particular, "The digital transformation of enterprises should let customers and the ecological partners and value chain partners of the entire enterprise feel the value brought by digital transformation and drive a virtuous cycle." Combined with the experience of industrial Fulian in building a number of lighthouse factories, Liu Zongchang also proposed that on the road to building a lighthouse, "building a large-scale ability can continuously reduce the marginal cost of digital technology application", and then empower more industries and regional industries, light up more lighthouses from point to line and surface, and help China's manufacturing industry to successfully transform.
Digital manufacturing platform
In the actual lighthouse exploration road, Industrial Fulian also consciously practiced the value initiative of the lighthouse factory - not only built 10+ light-out factories internally, and after winning the first batch of world lighthouse factories, Industrial Fulian through the Fii Cloud platform will be the lighthouse factory overall solution and digital manufacturing platform and industrial applications to electronics, automotive, machinery, residential home, energy and other industries leading services, to help enterprises of different sizes to achieve from "lighthouse factory" to "lighthouse group" leap. For regional industrial clusters, Fulian Has also innovated a set of empowerment models to strengthen regional cluster innovation based on the regional industrial Internet platform, achieve high-quality development of enterprises in the cluster, and enhance the comprehensive competitiveness of industrial clusters.
< h1 toutiao-origin="h2" > beacon pilot, ecological co-construction</h1>
It is worth mentioning that Industrial Fulian also launched the "Lighthouse Navigator Program", which aims to help 10 leading enterprises build into world-class lighthouse factory transformation benchmarks in the next 5 years; help 100 leading enterprises achieve complete digital transformation; introduce digital technology applications for 1,000 manufacturing enterprises; provide industrial and technical services for 50,000 small and medium-sized enterprises through the platform, and jointly create and discover new lighthouses in more industries.
Lighthouse Navigator Program
Dr. Huang Pei, CEO of e-works Research Institute, highly recognizes the professionalism and authority of the lighthouse factory business of Fulian Industrial, and hopes to jointly provide a set of digital transformation promotion guidelines for the majority of manufacturing enterprises through this cooperation, provide innovative practice benchmarks for smart factory construction and even the entire intelligent manufacturing field, and "lighthouse factory" as a guiding light to promote the successful realization of digital transformation of enterprises.
Li Zhiguang, manager of the aluminum wheel No. 6 factory of CITIC Dicastal Co., Ltd., shared the experience of lighthouse construction in the global auto parts industry in depth, and comprehensively dismantled the world development path of Chinese automotive enterprises from multiple dimensions such as project start-up, construction results, and future development: under the top-level design and planning, the implementation of digital lean manufacturing collaboration platform, global X-ray intelligent judgment and process closed-loop control, machine-added intelligent quality closed-loop system, highly flexible wheel hub automatic production line, and manufacturing-oriented new product intelligent R&D platform. In the end, the operational benefits of reducing production costs by 33%, improving the overall efficiency of equipment by 21.4%, reducing product defect rate by 20.9%, and shortening product delivery time by 37.9% were achieved, and won the honor of the new WEF World Lighthouse Factory in 2021.
Also as the representative of the new lighthouse in 2021 - Foxconn Wuhan Factory, through the real scene and sharing of the factory, the electronic manufacturing industry showed the construction secrets of the electronic manufacturing industry in improving the level of customization and shortening the delivery cycle, introduced advanced analysis and flexible automation technology on a large scale, redesigned the manufacturing system, increased the direct labor productivity by 86%, reduced the quality loss by 38%, shortened the delivery cycle to 48 hours, and finally became the first certified global lighthouse factory in Hubei and Wuhan.
Under the wave of digitalization, digital transformation is necessary and urgent. As a leader in digital transformation, lighthouse factories have played a driving engine role in promoting technological innovation, digital transformation and green sustainable development in China's manufacturing industry. The release of the white paper "Lighthouse Factory Leading the Digital Transformation of manufacturing Industry" will continue to release the lighthouse effect, encourage more and more Chinese manufacturing enterprises to move towards the "lighthouse", devote themselves to intelligent manufacturing and digital transformation, continuously light up new "lighthouses", and continuously sail to the new blue ocean of value of digital transformation.