Although the enthusiasm for smart factories is increasing, the penetration rate of smart factories is not high. Since 2014, the government has been providing related support to small and medium-sized enterprises together with large companies to spread smart factories, and last year announced that it would achieve 30,000 cases by 2022. However, even as 2023 dawns, the current number of projects completed was 19,779 as of the end of March 2023, far below the target.

There are many reasons, but the reluctance of many small and medium-sized manufacturing companies to adopt them also plays a role. Even if the efficiency is increased by applying the smart factory, it is difficult to clearly grasp the figure, and there are various problems such as cost and factory shutdown during the construction period for installation. We need groundbreaking smart factory solutions that can fundamentally change this passive attitude of companies.

 

Turn an old factory into a modern smart factory at minimum cost

Smart factory solution: FACTOROID

Gentle Energy Corporation (CEO Charles Kiseok Song) is a startup specializing in the development of smart factory solutions that has developed Factoroid, a smart factory solution that provides various KPI-based information, or insights, to the management and the workers of a factory. 

The importance of smart factories is increasing day by day, but many factories are hesitant due to various problems. Costs are quite burdensome, and above all, there is a risk of not meeting sales targets because the plant must be shut down to introduce new facilities. For this reason, many manufacturing companies are hesitant to introduce smart factories even as they witness a shortage of manufacturing manpower, rising labor costs, and a decrease in competitiveness due to aging facilities. Good news is that Factoroid can be easily introduced without downtime or cost thanks to non-construction AI sensors. The sensor does not require separate communication and wiring work, and the diagnostic program is provided before the solution is introduced, minimizing the cost of introduction. The fact that Factoroid is a comprehensive smart factory solution that provides hardware, AI, and software also has the advantage of minimizing the introduction cost.

Above all, Factoroid boasts high versatility. One of the main reasons manufacturers are frustrated when trying to introduce new equipment is the lack of versatility in terms of format, communication agreements, input power, etc. However, by applying a unique universal AI engine and sensor, Factoroid can be introduced regardless of the industry, equipment type, and equipment manufacturer. It has already succeeded in building solutions in various fields such as metal processing, automotive parts, air conditioners, electronic components, special steel, and injection molding, and thanks to these advantages, Factoroid is regarded as a solution that will help the manufacturing industry regain its lost vitality.

 

Providing efficient management insights

IoT system optimized from self-generating smart sensors

Factoroid provides real-time data and site information to detect inefficiencies in aging factories and derive insights into ways to improve. Factoroid displays a variety of real-time data and analysis to the management as well as the workers, enabling the management to identify inefficiencies in facilities and operations and gain insight into how to improve them. 

The key to realizing this function is an AI sensor with self-generation technology. When the sensor is attached to the equipment, it automatically measures the equipment’s inherent energy such as light, vibration, and current without a separate power supply. This self-generating sensor does not require battery replacement and semi-permanently collects real-time data without interrupting measurements. As data collection is automated, the number of people and time for data collection can be greatly reduced. Of course, it also prevents missing and incorrect data, so that even if a problem occurs, it can be quickly responded.

The measured data is transmitted through Gentle Energy’s self-built IoT system. Gentle Energy has built optimized data communication through its own gateway and maximized reception. Thanks to this, real-time and always-on monitoring is possible without missing data, boasting high security. The collected data is easy for anyone to see, resulting in high user visibility, and the intuitive and easy interface reduces user adaptation time. In addition, data and information derived from it can be viewed in the user’s desired device environment such as PC and mobile. 

 

Monitor KPIs with optimized data analysis models

Reducing operating costs and contributing to carbon neutrality

Factoroid even includes a data analysis engine that can analyze the data it collects. Gentle Energy’s AI engine analyzes various types of equipment data with a unique algorithm. It is also possible to cross-verify these analysis results to analyze precision production such as idle time, laying the foundation for management insights. These analysis engines have the function of deriving information from data through AI analysis, so that optimized data analysis models can be applied, and machine learning-based productivity analysis is also possible, so that factories can be monitored and managed based on KPIs (Key Performance Indicators).

Factoroid has a top-of-the-line algorithm that can distinguish the operation status in detail and precisely, and through this, it is possible to precisely analyze the uptime and idle time to derive key management indicators such as actual annual production capacity and optimal number of operating personnel. Even if the factory equipment is augmented with sensors, the signals collected through this augmentation can be analyzed with AI, so KPI management is easy. Thanks to this precise analysis system, it is possible to reduce factory costs and even improve efficiency. By analyzing productivity, it is possible to distinguish meaningless time and establish optimal production plans, thereby improving productivity per hour and per person, thereby reducing unnecessary maintenance costs and inefficient labor costs. In addition, it can also reduce power usage in conjunction with the production status. This goes beyond simply reducing the cost of operating the plant but also reducing carbon emissions by less electricity usage. The fact that the sensors used in Factoroid are self-generating also aids this.

As such, Factoroid specializes in production management and automation solutions. With this confidence, Gentle Energy is building an international brand recognition based on this. The company won the silver prize at the Edison Awards in April last year, and signed a facility productivity monitoring solution agreement with LG U+ in September. In October, the company was designated as a ‘Hi Seoul Company’ recognized by the Seoul Metropolitan Government and the Seoul Business Agency. 

권동호 기자  dongho2010@naver.com