DUBLIN, Ireland—Eaton Corp. has modernized its manufacturing footprint with smart factories in Juarez, Mexico, and Changzhou, China. 

As both a new build and legacy site, respectively, these electrical manufacturing sites have embraced Industry 4.0 technology and its benefits to digitalize operations. The Juarez and Changzhou assembly plants will serve as models for other Eaton factories, to help accelerate the implementation of advanced digital technologies.

Industry 4.0 leverages automation of traditional manufacturing practices using digital technologies like the Internet of Things (IoT), robotics, additive manufacturing, factory simulation, and augmented and virtual reality to adapt, predict and optimize factory performance. These technologies improve the efficiency of plants, leading to higher product quality, increased speed-to-market, a reduced environmental footprint and a safer and more productive workforce.

“Now, more than ever, there’s an expectation for manufacturers to optimize production, enhance customer experience, and enable innovation, driving the need for the benefits of Industry 4.0 solutions,” said Craig Sutton, vice president for Industry 4.0 at Eaton. “Our plants in Juarez and Changzhou have worked tirelessly to implement the advanced technologies needed to create smart and connected manufacturing environments that will help meet demand.”

The Juarez assembly plant began operations less than two years ago. It was built from the ground up with Industry 4.0 in mind. Today, this smart and connected manufacturing site employs more than 500 people and has implemented 10 Industry 4.0 technologies. Connected equipment spans every corner of the facility, including molding, stamping, automated feeder lines, manual and automated assembly, subassembly, and facilities equipment. This connectivity has led to an 18 percent improvement in on-time delivery. Digital work instructions provide updates in real-time based on production and design changes, creating an almost paperless environment.

The site also utilizes Eaton’s own Asset Performance Management software, part of the Brightlayer Industrial suite, to track and analyze energy usage, resulting in increased energy efficiency, reduced energy consumption, and early identification of significant energy users to reduce emissions and help meet the plant’s sustainability goals. The site has been certified as LEED Gold by the U.S. Green Building Council, and it recycles or reuses 99.8 percent of all waste generated at the facility.

Operating for nearly two decades and employing more than 370 people, the Changzhou site has implemented advanced technologies including additive manufacturing, factory simulation, autonomous robots, and augmented reality, among others, to digitalize its operations and realize a 26 percent increase in overall factory efficiency. A connected learning center provides employees with an immersive learning experience before they enter the factory floor.

Eaton’s Intelligent Energy Management system integrates digital and intelligent equipment at the site to optimize power supplied from utilities, solar panels and battery systems. The system monitors all electrical power usage at the site in real time and reports any abnormalities, allowing for early identification and detection of energy-saving opportunities. Since 2018, Changzhou has decreased greenhouse gas emissions by 50 percent.