[AI Autonomous Manufacturing Opens the Future] From BMW to BYD... AI Leads the Dark Factory Revolution

AI Robots Begin Replacing Humans in Assembly and Inspection
Foxconn and Tesla Achieve Both Quality and Efficiency with AI
Europe Is No Exception... Siemens and Sachsenmilch Build an AI Frontline

Artificial intelligence (AI) autonomous manufacturing is no longer a story of the future. In the production sites of global companies, AI is already quietly and tirelessly leading processes in place of humans. Global corporations such as BMW, Foxconn, Tesla, and BYD have implemented autonomous manufacturing systems in which AI is responsible for assembly, inspection, and maintenance, achieving both unmanned operations and high precision. The era has truly begun in which AI not only automates tasks but also makes decisions and leads production.

In September last year, Germany's BMW Group officially announced that it had deployed the latest humanoid robot, Figure 02, from the American robotics startup Figure, into its production line at the Spartanburg plant in South Carolina, USA. BMW shared this news on its official website with the slogan, "The future starts today."

Figure 02 has a human-like form, standing 170cm tall and weighing 70kg, and can precisely handle parts weighing up to 20kg with both hands. According to BMW, the robot can autonomously perform complex tasks such as placing sheet metal parts onto fixtures or assembling intricate components by hand.

BMW expects this robot to either collaborate with humans in the assembly process or replace repetitive and physically demanding tasks. Milan Nedeljkovic, BMW AG's Head of Production, stated, "Through initial pilot operations, we are closely reviewing the feasibility of applying humanoid robots to production sites," and added, "We want to develop this technology together from the development stage through to industrialization."

Sachsenmilch Leppersdorf GmbH, a dairy processing company located in Saxony, Germany, is one of the largest dairy factories in Europe, processing 4.7 million liters of raw milk every day. Operating 24 hours a day, 365 days a year, this factory must maintain an uptime rate close to 100%.

Recently, Sachsenmilch partnered with Siemens to introduce the AI-based predictive maintenance system 'Senseye.' This system analyzes equipment data to detect signs of failure early and focuses on preventing unplanned downtime. Roland Siepel, Sachsenmilch's Chief Technology Officer, stated, "After introducing Senseye, we detected pump anomalies early and saved hundreds of thousands of euros in costs."

Figure 02 is the latest humanoid robot developed by the robot company Figure, with a human body shape approximately 170cm tall and weighing 70kg. It is currently operating at the BMW Spartanburg plant in South Carolina, USA. BMW official website.

Foxconn of Taiwan is considered a leading company driving AI-based manufacturing innovation. As a key partner of Apple, Foxconn has adopted digital twin technology, AI-based quality inspection, and automated assembly systems through its subsidiary Foxconn Industrial Internet (FII), achieving unmanned operation rates of over 90% on some production lines.

At its factories in China, Foxconn uses Huawei's AI chipset 'Ascend' platform to conduct quality inspections of power control devices with artificial intelligence. A deep learning-based computer vision system detects the application of silicone grease and the attachment of nameplates in real time, reducing defect rates.

Market research firm Emerj highlighted Foxconn's collaboration with Siemens to apply digital twin technology to AI server production lines, analyzing that this has reduced energy consumption by more than 30%, improved process efficiency, and even enhanced profitability.

Chinese electric vehicle manufacturers BYD and NIO are also actively deploying AI humanoid robots. 'Walker S1,' developed by Chinese robotics company UBTech, is performing various tasks at BYD factories, including screw assembly, parts sorting, and quality inspection. Standing 172cm tall and weighing 76kg, Walker S1 uses visual recognition and AI algorithms to carry out precision tasks and is integrated with unmanned logistics systems, enabling full automation of the production process.

NIO plans to replace 30% of its total workforce with AI robots by 2027. UBTech is promoting a transition in which robots handle more than 70% of process automation, while humans focus on management and collaboration. The technology magazine Interesting reported in October last year, "UBTech has secured more than 500 orders for Walker S1 from major automakers," and analyzed that the adoption of automation technology for operational streamlining will also help solve labor shortages in China's manufacturing industry.

FANUC of Japan, which has realized the concept of 'robots making robots,' is a leading example of a dark factory (a factory that does not require lighting). At FANUC's robot production line in Oshino, Yamanashi Prefecture, operations are conducted unmanned for about 30 days without human intervention. Up to 50 robots are produced per day, and the entire process is controlled by a remote monitoring system. The factory operates without heating or cooling, resulting in excellent energy efficiency, and AI and robotic systems are precisely integrated from parts processing to assembly, inspection, and packaging.

In May 2023, Reuters reported on Tesla's 'Unboxed' manufacturing method, quoting CEO Elon Musk as saying, "To mass-produce more affordable and profitable electric vehicles, we must radically redesign traditional automotive manufacturing." This method is designed to reduce production costs, shrink factory size, and improve vehicle production efficiency. Unlike the traditional assembly line approach, the car body is divided into submodules and assembled in parallel, enabling a 40% reduction in factory size and up to a 50% reduction in costs.

AI autonomous manufacturing is drawing attention as a 'game changer' that goes beyond simple automation to overcome various industrial risks, such as uncertain supply chain environments, shortages of skilled labor, and rising production costs. Experts predict that within the next 5 to 10 years, a significant portion of major manufacturing processes will be replaced by AI and robots.

The Financial Times (FT) reported in March last year that "a wave of AI-based humanoid robots is arriving on manufacturing lines," and predicted that within the next five years, AI will handle core processes such as equipment operation, assembly, and maintenance. Jensen Huang, CEO of Nvidia, also emphasized, "Robots can work in more dangerous environments than humans, operate 24 hours a day, and carry heavy objects," highlighting that a change on the scale of the industrial revolution is imminent.

Morgan Stanley analysts forecast that cumulative sales of humanoid robots will reach 900,000 units in 2030, 134 million units in 2040, and 1.02 billion units in 2050.