Anyang Kayo Amorphous Technology Co.,Ltd. , https://www.kayoamotech.com
Deep sniffing "Industrial 4.0" industrial automation takes you to touch the digital factory
While the concepts of "Industry 4.0" and digital factories were gaining traction in the industry, I had the opportunity to visit the Chengdu Production R&D Base (SEWC) of Siemens Industrial Automation in the Hi-Tech West District of Chengdu. This experience gave me a firsthand look at how Siemens is implementing these cutting-edge ideas in China. As the first and only digital factory of its kind, SEWC provided a tangible example of what "Industry 4.0" truly means.
The visit was eye-opening, offering a deeper understanding of how digitalization transforms manufacturing. The concept of “seeing is believing†truly resonated with me as I observed the seamless integration of automation, data flow, and smart systems in action.
SEWC is a sister plant to the renowned Amberg factory, often regarded as the global benchmark for digital manufacturing. Established in 2011 and operational since 2013, SEWC has quickly proven itself as a model of efficiency and precision. According to Li Yongli, General Manager of Siemens Industry Automation (Chengdu), the factory can produce one product every 10 seconds, with an impressive 11,000 units per day and just 9.5 million machining failures per million (dpm). A significant portion of its products are shipped globally, including to Germany.
Li emphasized that SEWC isn’t just about building a model factory—it’s about achieving better performance, higher quality, and faster delivery. He explained that customers care more about product quality than price alone, as the cost of failure far exceeds the product's value. Digital systems help track every step of the process, ensuring transparency and enabling quicker decision-making.
Automation plays a key role in improving quality, reducing human error, and collecting real-time data efficiently. From logistics to information flow, each process is optimized to ensure accuracy and speed. For instance, automated material handling ensures traceability and reduces waste, while integrated software platforms like ERP, PLM, and MES enable seamless communication across departments.
At the core of SEWC is a transparent factory environment where data flows freely between systems. The integration of production, design, and supply chain management allows for real-time monitoring and quick adjustments. This level of connectivity not only enhances efficiency but also supports continuous improvement.
During my tour, I saw how the factory operates with minimal manual intervention. Materials move through guided rails, scanned automatically, and transported to the right location. The assembly lines use electronic task lists, and sensors record data at each stage, feeding into the MES system for real-time quality checks.
In the three-dimensional warehouse, materials are stored in high-rise shelves, accessed by automated stackers that retrieve items with pinpoint accuracy. This system minimizes errors and maximizes space utilization.
Overall, the visit was a valuable learning experience. It showed me that digitalization isn't just about replacing humans with machines or following a step-by-step approach. It's about rethinking traditional models and building new systems that drive innovation and efficiency. SEWC exemplifies how Industry 4.0 can transform manufacturing, making it smarter, faster, and more reliable.