[Report] Visiting Korea's First Clean Energy Smart Factory 'Sinsung ENG Yongin Plant'

Power 40% Supplied by Solar Energy... Robots and Workers Collaborate to Supply Samsung, LG, etc.
Production of Semiconductor Factory Automation Equipment and Cleanroom Equipment
Worker Task Programming
Coexistence with Robots Leads to Increased Staff
Aiming to Advance 'K-Smart Lighthouse Factory'

A view of Shinsung ENG Yongin Factory located in Cheoin-gu, Yongin-si, Gyeonggi-do.

[Asia Economy Reporter Donghyun Choi] The Sinseong ENG Yongin Plant located in Cheoin-gu, Yongin-si, Gyeonggi Province. This is Korea's first clean energy-based smart factory, equipped with solar panels installed on all building rooftops and idle land. With a total solar power generation capacity of 639KW and an energy storage system (ESS) with a capacity of 1200kWh, it supplies 40% of the entire factory's electricity consumption. A Sinseong ENG official stated, "We purchase electricity from Korea Electric Power Corporation (KEPCO) during the cheaper nighttime hours and rely on solar power generation during the most expensive daytime hours," adding, "If there is sufficient idle electricity in the ESS, we also sell the electricity we produce back to KEPCO."

Sinseong ENG Producing Essential Equipment for Advanced Materials: 'Clean Rooms'

Established in 1977, Sinseong ENG manufactures advanced industrial products such as semiconductor and display factory automation equipment, clean room facilities, and solar modules. The Yongin plant, built as a smart factory, was completed in 2016.

Upon entering the factory, a large monitor displays a 3D video of the production line constructed like a 'Metaverse' (extended virtual world). Above the heads of moving workers on the screen, a 'stamina gauge bar' similar to those seen in games is visible. When workers lift or move products and expend energy, the gauge decreases accordingly. This system, called 'CPS' (Cyber Physical System), is implemented at the Yongin plant to program workers' motions and measure real-time workload and time, thereby improving work efficiency. A Sinseong ENG official explained, "If a worker's stamina gauge decreases significantly in a short time, more production resources are allocated," adding, "It is also possible to compare and verify standard working times with real-time working times."

The 'CPS' (Cyber Physical System) established at Shinsung ENG's Yongin factory programs workers' movements to measure real-time workload and time, aiming to improve work efficiency.

The main product of the Yongin plant is clean room equipment. A clean room is a controlled space where airborne particles, air temperature and humidity, and indoor pressure are maintained at constant levels. Since advanced material fields such as semiconductors, secondary batteries, and biotechnology require strict management where even a single fine dust particle can cause defects, the demand for clean rooms has recently increased in related industries. Sinseong ENG holds over 60% market share in the 'Fan Filter Unit' (FFU) market, a key clean room equipment.

In one corner of the factory, products destined for Samsung Electronics and LG Display were being packaged and prepared for shipment. Last month alone, Sinseong ENG signed clean room equipment supply contracts worth a total of 77.1 billion KRW with companies including Samsung C&T, SK Hynix, and LG Display.

Human-Robot Relationship: Not Confrontation but Coexistence and Cooperation

When news of smart factory construction spreads in industrial sites, workers are not always pleased. This is due to concerns that robots might take away their jobs. This is especially true nowadays, as digital transformation across industries makes unmanned and automated operations a societal imperative. However, such sentiments were not detected among the workers met at Sinseong ENG Yongin Plant.

When the Yongin plant was established in 2016, there were about 40 employees. Currently, the number has increased to 54, with about 10 more workers. A Sinseong ENG official said, "Although there was an estimate that more than 10 workers could be reduced after building the smart factory, we did not do so," emphasizing, "If workers previously performed simple assembly tasks, their roles have now shifted to engineers operating equipment, increasing job satisfaction and further advancing the system."

At Shinsung ENG's Yongin factory, a collaborative robot (Cobot) is assisting workers with their tasks.

On one production line inside the factory, there is equipment called a 'Collaborative Robot' (Cobot). Usually, when a robot is near a person, there is a risk of accidents due to physical collisions, so people tend to avoid close proximity. However, the simplified and lightweight collaborative robot reportedly causes no harm to workers. It is designed to stop automatically when a worker approaches. The Cobot was scanning the condition of a product next to a worker and quickly performing simple tasks such as tightening bolts with its robotic arm. Additionally, unmanned guided vehicles (AGVs) and autonomous logistics robots were also working 'separately yet together' with workers, keeping a busy day.

Advancing the 'K-Smart Lighthouse Factory'... "Targeting 80% Process Automation Rate This Year"

Last year, Sinseong ENG Yongin Plant was selected as a 'K-Smart Lighthouse Factory' by the Ministry of SMEs and Startups. The K-Smart Lighthouse Factory is a leading smart factory program centered on small and medium-sized enterprises, benchmarking the 'Global Lighthouse Factory' selected mainly for large corporations by the World Economic Forum (WEF). Through this program, the Yongin plant will receive up to 1.2 billion KRW in support for smart factory advancement costs by next year.

Park Deok-jun, Yongin Plant Manager at Shinsung ENG

Park Deokjun, the Yongin Plant Manager of Sinseong ENG, who has been working for 28 years (56 years old, pictured), said, "There are almost no cases of smart factory construction at this level in medium-sized and small enterprises," adding, "Many medium and small enterprises seeking to build smart factories are requesting consulting, and we are providing support."

Since adopting the smart factory, Sinseong ENG's annual production volume has increased by 210%, and the defect rate has decreased by 97%. According to Manager Park, the per capita production was 0.94 units in 2017 but increased to 1.51 units last year. Park stated, "Our goal this year is to achieve an 80% process automation rate," adding, "Rather than expanding externally, we will focus on strengthening internal capabilities and further advancing the smart factory."