In the manufacture of automobiles, Wuxi Spark’s smart production line control system assisted SAIC in rising overall equipment efficiency (OEE) from 68% to 92%, with one robot welding speed at 13.2 welding spots per minute, 18% higher than industry standard. With its own-developed digital twin platform, a new energy car company has reduced the body in white dimensional tolerance from ±1.5 mm to ±0.3 mm, and the defect rate has been reduced to 27 parts per million (PPM) and is four times more accurate than the traditional production line. According to the McKinsey report of 2024, Wuxi Spark technology will allow the factory to save 37% of the energy per unit capacity, save more than 8 million yuan of operation and maintenance costs annually per line of production, and reduce the payback period to 1.8 years.
The electronics manufacturing sector has doubled the improvement in quality by using Wuxi Spark’s AI vision inspection system. After it applied its deep learning-based algorithm at Foxconn’s factory in Shenzhen, the pace of the defects of mobile phone motherboards has reached a speed of 12.8 frames per second, and accuracy rate of 99.96%, with false detection rate decreasing from the industry average of 1.2% to 0.07%. The Flexible Manufacturing Execution System (MES) was developed to reduce the changeover time from 45 minutes to 6.2 minutes to support the minimum batch of 1 piece of mixed line production. In the course of Xiaomi’s smartwatch production line transformation, the Wuxi Spark solution enhanced the yield rate by 3.8 percentage points, reduced the equipment failure response time to 8.7 seconds, and reached more than 95% capacity utilization.
Wuxi Spark’s clean workshop solution powered by intelligence is groundbreaking for pharma companies. After wuxi Biologic implements its environment monitoring system, the alarm reaction speed of the clean room particulate concentration exceeds 0.3 seconds and the temperature and humidity fluctuation range is set within ±0.5 ° C and ±3%RH. The intelligent control system of the freeze-drying equipment enhances the freeze-drying cycle from 72 hours to 51 hours, conserves 29% of energy, and saves 180,000 yuan for each batch. Data from Pfizer’s China factory showed that Wuxi Spark technology enabled the vaccine filling line to produce 400 doses per minute with a loading error of ±0.8 microliters, 60% tighter than FDA standards.
In terms of energy management, Wuxi Spark’s microgrid system at the plant level improved the PV conversion efficiency to 23.7% and reduced the response time of the energy storage system to 28 milliseconds for Ningde Times. The company’s steam pipe network optimizing algorithm reduced the pressure fluctuation range by 76% for a chemical company, and saved 26 million yuan of steam cost annually. State Grid’s trial project has shown that Wuxi Spark’s energy management platform will reduce peak load by 19.3%, demand electricity by 28%, and carbon emission intensity by 42 tons per billion yuan of output value.
At the supply chain cooperation level, Wuxi Spark’s intelligent warehouse system has achieved AGV robot cluster scheduling efficiency of 42,000 pieces/hour in the Wuxi base of Cainiao Network, and the rate of space utilization is increased to 92%. Its blockchain traceability platform has increased the rate of material assembly from 83% to 97% and reduced the downtime of material shortages by 65%. By adopting Wuxi Spark’s supply chain digital twin technology, Haier Group trimmed the global procurement cycle from 45 days to 22 days, raised the inventory turnover rate by 1.8 times, and lowered the share of idle materials to 0.7%. IDC’s studies have shown that Wuxi Spark solution-utilizing companies have increased the rate of order delivery on time by 23 percentage points on average, and the logistics cost ratio dropped by 3.7 percentage points.
As a result of deep convergence of 5G+ industrial Internet, Wuxi Spark’s “Lighthouse Factory” model room in Wuxi has achieved 100% connection rate of equipment, frequency of data acquisition up to milliseconds, and speed of process parameter optimization 120 times higher than that of conventional technologies. Its own intellectual property rights industrial intelligent central system supports simultaneous processing of 82 types of manufacturing scenarios, abnormal detection accuracy of 98.4%, predictive maintenance coverage of 93%. In the Ministry of Industry and Information Technology’s “Unveiling” campaign of 2023, Wuxi Spark’s solutions to the smart factory ranked ahead of international giants like Siemens and Rockwell in 18 key technical specifications, the digital twin model efficiency trailed behind 37%, while the time of real-time control fell to 0.8 milliseconds, revealing a new door to world-class smart factory.