APS / Digital Twin / Object Recognition
AI-based Intelligent Production Planning
and Simulation Solution
Is your factory still struggling with unpredictable production plans and quality issues? KULS’s AI-based Smart Factory Solution delivers a 30% increase in production efficiency, a 50% reduction in defect rates, and a 35% decrease in maintenance costs all at once. We revolutionize your manufacturing site with the power of real-time data and artificial intelligence.
Introduction to Core Technologiess
APS (Advanced Planning And Scheduling)

With a real-time data-driven production planning optimization system, limited resources
(equipment, manpower, and raw materials) are efficiently allocated to automatically generate the optimal production schedule. Dynamic planning enables rapid response to sudden market changes and urgent orders.

Digital Twin

A digital twin that perfectly replicates the actual production site, synchronized in real-time through IoT sensors. Simulate various scenarios before actual operations to determine optimal strategies, and maximize equipment uptime through predictive maintenance.

Object Recognition

Using AI-based computer vision technology, products, components, and defective items on the production line are automatically identified in real-time. Overcoming the limitations of visual inspection,it accurately detects even the smallest defects and automatically collects quality data to enhance the quality management system.

AI-based Smart Factory System Diagram
Implementation
Benefits

01

Productivity Improvement
- 20–30% Increase in Production Efficiency: Maximize Equipment Utilization with AI-based Optimal Scheduling
- 15–25% Reduction in Lead Time: Real-time Production Monitoring and Rapid Decision-Making
- Inventory Optimization: Reduce Inventory Costs by 20% through Improved Demand Forecast Accuracy

02

Quality Improvement
- Over 50% Reduction in Defect Rates: AI-Based Real-Time Quality Inspection and Prevention
- Ensure Quality Consistency: Automatic Application of Standardized Quality Criteria
- Improved Customer Satisfaction: Reduce Complaints by Ensuring Quality Stability

03

Cost Reduction
- Labor Cost Reduction: Optimize Workforce Allocation Through Automation
- 10–15% Energy Cost Savings: Optimize Equipment Operation and Predictive Maintenance
- 30% Reduction in Maintenance Costs: Planned Maintenance through Predictive Servicing

04

Decision Support
- Real-time Status Monitoring: Instant Situation Awareness via Integrated Dashboard
- Data-Driven Decision Making: Providing Objective Analytical Data
- Scenario Analysis: Pre-Simulation Using Digital Twin
Application Areas
Manufacturing
ㆍAutomotive Assembly Line Optimization, Component Quality Inspection, and Production Planning
ㆍElectronics / Semiconductors Precision Inspection, Cleanroom Environment Management, and Yield Improvement
ㆍSteel / Metals Process Temperature Control, Product Specification Inspection, and Predictive Equipment Maintenance
ㆍChemical / Petrochemical Batch Optimization, Safety Management, and Ensuring Quality Consistency
Industry-Specific Use Cases
ㆍFood / Pharmaceuticals HACCP Compliance, Shelf-life Management, and Batch Traceability
ㆍTextiles / Apparel Dyeing Process Optimization, Cutting Accuracy, and Inventory Management
ㆍPlastics Injection Molding Condition Optimization, Visual Inspection, and Raw Material Blending Management
ㆍMachinery / Equipment Assembly Process Management, Performance Testing, and Shipping Quality Assurance
Industry-Specific Use Cases
ㆍFood / Pharmaceuticals HACCP Compliance, Shelf-life Management, and Batch Traceability
ㆍTextiles / Apparel Dyeing Process Optimization, Cutting Accuracy, and Inventory Management
ㆍPlastics Injection Molding Condition Optimization, Visual Inspection, and Raw Material Blending Management
ㆍMachinery / Equipment Assembly Process Management, Performance Testing, and Shipping Quality Assurance
By Process Type
ㆍContinuous Process 24/7 Continuous Operation Optimization and Real-Time Quality Monitoring
ㆍBatch Process Batch Condition Optimization and Yield Maximization
ㆍAssembly Process Work Sequence Optimization and Component Supply Management
Step-by-Step Approach for Successful Implementation
STEP 01
Current State Analysis and Plan Development

ㆍAssessment of Current Production Systems and Data Infrastructure

ㆍDefine Implementation Goals and Calculate ROI

ㆍDevelop a Step-by-Step Implementation Roadmap

STEP 02
Pilot Implementation

ㆍPilot Application on Key Processes

ㆍEstablish Data Collection System

ㆍDevelopment and Validation of Basic AI Model

STEP 03
Deployment and Enhancement

ㆍFull-Scale Deployment Across All Processes

ㆍRefinement and Optimization of AI Models

ㆍExecutive Training and Internalization

STEP 04
Operational Optimization

ㆍContinuous Monitoring and Improvement

ㆍAdditional Feature Expansion and Enhancement

ㆍDeployment Across Other Plants/Lines