The CATL-Fuding Plant is a leading global production base in the lithium-ion battery industry. As a global leader, the factory integrates Industrie 4.0 technologies to achieve “Extreme Manufacturing” and sustainable development. Powered by its innovative “Extreme Manufacturing + Digital Intelligence + Zero Carbon Cycle” system, it successfully established a new benchmark for smart manufacturing and low-carbon development in the industry.
Facing the challenges of rapid capacity expansion, strict energy and carbon control, precision process consistency, and equipment reliability, the plant implemented a comprehensive Industrie4.0 transformation plan. Through the deployment of AI, Big Data, Digital Twin, and 5G+IIoT technologies, the factory achieved full digitalization and intelligence from energy management to logistics. The Industrie 4.0 solution include:
To address high energy consumption in core coating processes, an intelligent closed-loop control system was developed. Utilizing an IIoT sensor network to collect 74 variables (such as wind frequency, temperature, and NMP concentration) and AI deep learning algorithms, the system enables second-level analysis and dynamic optimization. This reduced coating energy consumption costs by 2.16 kgce/kWh and lowered carbon emissions by 172 Ton/GWh.
A predictive maintenance platform covering thousands of devices was established using 5G networks and AI models. Combined with a knowledge graph-based Intelligent Failure Analysis (FA) system, it enables rapid root cause positioning and fault warning. This reduced equipment failure rates by 60%, cut maintenance costs by 41%, and shortened single failure analysis time from 139.3 hours to 10.3 hours.
The factory deployed a 5G-based AGV smart logistics system seamlessly integrated with WMS and MES. By achieving unmanned handling and intelligent scheduling from raw materials to finished products, the system increased warehouse personnel efficiency by 80%, achieved 70% AGV utilization, and saved 90% of energy within the warehouse.
