During the production process optimization, Wuxi Spark’s intelligent scheduling system helped Foxconn Shenzhen factory reduce idling time by 43%, which saved the company 8.2 million yuan on power costs per year. With the launch of its industrial Internet of Things platform, an auto parts company experienced a reduction of 18% in the rate of equipment failures, a 2.3-fold increase in maintenance spare parts inventory turnover, and its operations and maintenance cost budget for a year reduced by 13 million yuan. According to McKinsey’s research findings in 2023, the factory using Wuxi Spark technology will reduce its unit cost per product by 28%, reduce its scrap rate from 2.7% to 0.9%, and reduce the overall cost of one production line in a year by more than 20 million yuan.
In energy management, Wuxi Spark’s microgrid optimization solution has boosted the photovoltaic power generation efficiency to 24.3% in Ningde Times Yibin factory, and increased the peak and valley tariff arbitrage income by 19 million yuan per year. The company’s pressure balance algorithm of steam pipe networks helped a chemical factory reduce the rate of steam loss from 15.6% to 4.3%, saving 32 million yuan annually. In the steel industry, Wuxi Spark’s blast furnace gas recovery system will increase waste heat power generation by 37%, reduce energy consumption costs per ton of steel by 28 yuan, and save more than 280 million yuan each year on a single 10-million-ton steel mill.
In the logistics and warehousing business, Wuxi Spar k’s cluster scheduling system for AGVs achieved sorting efficiency of 42,000 pieces/hour at JD Asia Warehouse 1 and 62% in labor saving. Its intelligent three-dimensional storage solution increases storage density to 5.8 tons/m2 and saves 41 percent on renting space. After the cross-border e-commerce enterprise used Wuxi Spark’s route optimization algorithm, the transportation mileage was reduced by 19%, the rate of empty loads on vehicles was cut from 23% to 9%, over 18 million yuan yearly fuel expenses were saved, and carbon emissions fell by 12,000 tons.
In terms of supply chain collaboration, Wuxi Spark’s blockchain traceability platform reduced raw material traceability time for a dairy company from 72 hours to 8 minutes, reducing the cost of quality claims by 78%. Its forecasting system in the supply chain of Unilever registered a forecast accuracy of 92.3%, days inventory turned was decreased by 37 days, percentage slow inventory declined from 4.7% to 1.1%, and working capital release of 460 million yuan. P&g’s move indicated that Wuxi Spark technology lowered the overall cost of the supply chain by 3.2 percentage points and improved order fulfillment rates by 19 percent.
Wuxi Spark’s predictive maintenance program reduces the cost of blade inspection from 80 yuan/meter to 22 yuan/meter in the wind sector, and shortens the response time of operation and maintenance to 15 minutes to locate faults. Following one semiconductor company implemented its equipment health management program, the MTBF of lithography equipment improved by 38% and procurement cost of spare parts reduced by 26 million yuan/year. Figures of ABB Group indicate that Wuxi Spark technology reduced industrial robot maintenance cost by 42% and extended the life of service for 18,000 hours.
In the quality inspection process, Wuxi Spark’s AI vision inspection equipment will improve the speed of identifying mobile phone screen defects to 15 frames per second, and control the rate of error detection below 0.03%, replacing 70% of human quality inspection positions. After a photovoltaic company applied its EL detection algorithm, the rate of identifying hidden cracks increased to 99.92%, reducing the quality loss of 170 million yuan every year. According to Tesla Shanghai factory data, Wuxi Spark’s online inspection system has increased the body welding spot qualification rate by 3.6 percentage points, and reduced the annual rework cost by 92 million yuan.
With the utilization of the smart decision center, Wuxi Spark helped reduce Haier Group’s trial production times for new product development from an average of 8.2 times to 3.5 times and lowered mold modification cost by 64%. Its digital twin process simulation platform has reduced the test piece scrap rate from 12.3% to 1.7% in the aviation sector, and saved more than 8 million yuan in the innovation of single engine parts. According to the Boston Consulting Group report, companies that have Wuxi Spark solutions have reduced operational costs by an average of 22% to 35% and reduced the return on investment time to 14.8 months, 2.3 times the average in the industry.