Generative AI Slashes False Defect Rate to Zero

From parts supply to assembly and packaging, automation takes over. The 2023 generative AI boom accelerates AI adoption, advancing digital twins in partnership with NVIDIA, and managing even what human eyes cannot see. At LS ELECTRIC's factory in Cheongju, North Chungcheong Province, a camera-equipped robotic arm was taking images of finished circuit breaker products from all angles (top, bottom, left, and right). The photos taken by the robot are analyzed in real time by artificial intelligence to check for defects. LS ELECTRIC introduced generative AI into its product inspection process in 2023, significantly improving work efficiency. A company official said: The probability of misreading a non-defective product as defective used to be 10 percent, but it is now 0 percent. Defect rate at 0.0007 percent after AI adoption. Building G at LS ELECTRIC's Cheongju factory, where the AI robotic arm has been deployed, has an automated system across the entire line from parts supply and assembly to testing and packaging. This facility produces 26 million industrial circuit breakers and 12 million contactors annually. Inside the factory, more than 20 automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) transport parts seamlessly according to programmed commands and AI-driven real-time traffic analysis. Only one or two employees per line are needed to monitor whether the process is running smoothly. LS ELECTRIC has enhanced process integrity to the point that the overall defect rate at the Cheongju factory has reached 7 PPM (7 per 1 million), one of the highest levels among global smart factories. The Cheongju factory's energy consumption efficiency is also continuously improving. LS ELECTRIC links production data with energy data to track and control the power consumption of equipment in real time, reducing energy use by more than 60 percent compared to before the system was introduced. Cho Uk-dong, head of LS ELECTRIC's AP and EMEA Business Division, said: This is becoming a powerful tool for proactively responding to demand fluctuations and optimizing productivity. The company also plans to introduce an AI agent solution that applies AI models to power equipment diagnostics.