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LG Home Appliance Factory in United States Latest to Receive Prestigious ‘Lighthouse’ Status

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January 16, 2023

LG Home Appliance Factory in United States Latest to Receive Prestigious ‘Lighthouse’ Status

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LG Electronics Tennessee Plant is Selected as Industry’s First U.S.
Home Appliance Lighthouse Factory by World Economic Forum

LG Electronics’ (LG) home appliance manufacturing plant in the United States has been selected as a world-leading Lighthouse Factory by the .World Economic Forum (WEF)

The million-square-foot factory in Clarksville, Tennessee – the U.S. production base for LG’s award-winning washers and dryers – is the industry’s first home appliance plant in the United States to join the WEF’s global network. Also, it is the company’s second Lighthouse Factory, following on the heels of the LG Smart Park in Changwon, South Korea, which was selected by the WEF last year.

A “Lighthouse Factory” is recognized by the WEF for its role in shaping the future of manufacturing through the integration of Internet of Things (IoT), big data, artificial intelligence (AI), robots and other Fourth Industrial Revolution technologies. Since 2018, the WEF has selected and added global factories to its network twice a year.

LG’s world-class autonomous factory in Tennessee utilizes advanced digital technologies from AI and big data to IoT and robots. Completed at the end of 2018, the facility now operates three production lines for front-load and top-load washing machines and dryers. With an annual production capacity of 1.2 million washers and 600,000 dryers, the plant proactively responds to changing North American demand through local production. More than 900 people work at the LG home appliance factory in Montgomery County, Tenn.

Featuring a complete integrated production system streamlined process to supply impeccable products to customers on time, each line carries out the entire manufacturing process of new models from making the parts to assembly and packaging. In addition, strict quality conditions are applied to all the assembly lines to heighten quality across the board, from parts to finished products.

The LG Tennessee factory boasts a fully autonomous logistics system with 166 automated guided vehicles (AGVs) that transport parts around the plant. With three times more AGVs than the LG Smart Park, these robots improve overall productivity by freeing up people for other tasks.

With the integration of parts production such as metal press processing, plastic injection molding, and painting – including LG’s own intelligent injection molding system – the company has increased component productivity by 21 percent.1 In addition, the plant recognizes and responds in advance to potential productivity issues through an advanced detection system. By applying data-based AI technology that accurately predicts washing machine performance, the number of tests and energy consumed during testing are reduced by 22 percent, while the defect rate has been reduced by more than 61 percent via quality optimization.2

The plant is also maximizing workplace safety and operational efficiency by using robots for complicated, potentially dangerous tasks, such as assembling and lifting heavy parts and welding.

To further improve efficiency, LG plans to establish a 5G connectivity network across the facility in the second half of this year, creating an environment where its many AGVs can transport materials faster and more accurately based on stable, uninterrupted communication. LG will also introduce Autonomous Mobile Robots that navigate the expansive facility with ease to enhance its logistics system.

LG’s commitment to sustainability can be seen throughout the Tennessee factory, which transitioned to renewable energy completely already in 2022. The plant also uses a high-efficiency utility infrastructure, which supplies the power, steam and heat necessary to produce LG’s home appliance products with the help of the company’s advanced Building Energy Control (BECON) solution.

“Along with the LG Smart Park, LG’s Tennessee factory represents our unmatched leadership in transforming manufacturing facilities into advanced, futuristic hubs utilizing the most revolutionary technologies,” said Lyu Jae-cheol, president of the LG Electronics Home Appliance & Air Solution Company. “Lighthouse Factory status exemplifies how LG continues to strive for providing differentiated customer experiences through customized manufacturing innovations

Arçelik: well-deserved recognition for the Turkish group

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Arçelik’s washing machine factory in Ulmi, Romania, ranked among the most advanced in the world in terms of environmental sustainability. Indeed, Arçelik, a global appliance manufacturer and subsidiary of Turkey’s largest industrial conglomerate, Koç Holding, has been awarded Sustainability Lighthouse status by the World Economic Forum (WEF) for its manufacturing plant . ‘Ulmi, Romania. A recognition that rewards effective measures in terms of energy performance applied on the site. This follows the already existing statusArçelik as a Global Lighthouse awarded by WEF to its Ulmi plant in 2019 and Eskişehir plant in 2021 for the successful adoption of Fourth Industrial Revolution (4IR) technologies to improve productivity and performances.

LG factory

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World Economic Forum Recognizes LG for Innovative Digital Transformation of Its Home Appliance Manufacturing Facility in South Korea   LG Smart Park, a production base of LG Electronics (LG), has been selected as a Lighthouse Factory by the World Economic Forum (WEF).

Shaping the future of manufacturing, WEF “Lighthouse” facilities implement Fourth Industrial Revolution technologies, such as the Internet of Things, big data, artificial intelligence and robots, into manufacturing and supply chain operations to deliver a wide range of benefits, from increased production efficiency to enhanced environmental sustainability.

LG Smart Park, LG Electronics’ home appliances factory in Changwon, Republic of Korea

‘Digital twin’ technology enables the operation system to analyze the production processes in virtual reality.

Refrigerator door attachment based on 3D vision recognition technology

Overhead conveyor system

“As the world grapples with many challenges, it is remarkable to see how Lighthouses are yielding sustainability benefits while achieving business goals, which we call eco-efficiency,” said Francisco Betti, Head of Shaping the Future of Advanced Manufacturing and Value Chains, World Economic Forum. “We need them to continue illuminating the way forward for the global manufacturing community by shaping a responsible future of manufacturing that works for people, society and the environment.”

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 while overall quality competitiveness[1] and production efficiency[2] were both significantly strengthened.

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.[1]

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 LG production facilities in 13 countries, accelerating the digital transformation of its global manufacturing network by 2025.

“LG Smart Park illustrates our strong commitment to adopting the revolutionary technologies as the leader of the global premium home appliance market,” said Lyu Jae-cheol, president of the LG Electronics Home Appliance & Air Solution Company. “We are presenting a blueprint for the future of manufacturing, one that delivers better outcomes across environmental, economic and employment aspects.”

For more information, please visit https://www.lgnewsroom.com/2022/03/lg-smart-park-named-lighthouse-factory-for-futuristic-manufacturing-technology/ 

[1]  Comparing the figures from the year 2020 to 2021 according to the lighthouse site visit report by World Economic Forum.

[2]  Units produced per hour has increased by 17 percent, comparing the year from 2020 to 2021 according to the lighthouse site visit report by World Economic Forum

About LG Electronics Home Appliance & Air Solution Company

The LG Home Appliance & Air Solution Company is a global leader in home appliances, smart home solutions, air solutions as well as visionary products featuring LG ThinQ AI. The company is creating various solutions with its industry leading core technologies and is committed to making life better and healthier for consumers by developing thoughtfully designed kitchen appliances, living appliances, HVAC and air purification solutions. Together, these products deliver enhanced convenience, superb performance, efficient operation and compelling health benefits.
 

SOURCE LG Electronics,