On November 27th, at the 2025 World Intelligent Manufacturing Conference, Zoomlion Excavator Factory was successfully selected as one of the first 15 pilot level intelligent factories cultivated by the country. From a steel plate to a complete machine, it only takes 6.5 days; On average, one excavator goes offline every 6 minutes, and its production pace, changeover time, and manufacturing cycle are among the world's leading... This leading intelligent factory breaks the global record for construction machinery manufacturing with extreme efficiency. What kind of "smart manufacturing" password is hidden behind it?
Driven by the "intelligent manufacturing" engine, reconstruct the entire production process
Entering the excavator factory, the roar and dust of traditional heavy industry workshops have disappeared, replaced by the precise cooperation of robotic arms in the "industrial symphony", as well as the technological landscape of AGV (Automated Guided Vehicle) small cars silently shuttling. On the panoramic monitoring screen, various data points jump in real time, and the operating status of more than 2000 sets of equipment, the flow trajectory of more than 100000 components, and the production progress of various models of excavators are clear at a glance. The entire production process is clearly visible.
In the intelligent storage area of the excavator factory, a reporter from Securities Daily saw a humanoid robot accurately selecting a certain component from a pile of parts, and then holding it in front of its eyes for careful inspection; After the inspection is completed, the robot quickly moves to the front of the parts sorting basket with the help of tracks, and then accurately puts the parts into the basket. After the AGV car senses the material entering the basket, it immediately responds and drives quickly to transport qualified materials away in a timely manner.
In the material preparation center workshop of the excavator factory, laser cutting machines accurately cut steel plates according to digital models, with cutting errors controlled within 0.1 millimeters. The robotic arm moves flexibly on different types of structural components like a skilled tailor. What's even more amazing is that when the production line switches from 5-ton excavators to 30 ton products, the robotic arm, conveyor line, and detection equipment can be automatically adjusted synchronously without stopping the entire process, achieving true "zero switching of production".
According to Shi Heng, the excavator factory has built 61 highly flexible intelligent production lines, equipped with more than 300 automatic logistics AGVs and more than 280 industrial robots, with a comprehensive automation rate of over 85%, and 100% full process collection and traceability of production data.
Through the construction of full scene intelligence, the production efficiency of the factory has been greatly improved. For example, the fully automatic drive seat processing production line combined with an intelligent digital production control system has increased production efficiency by 20% and achieved 100% data consistency. In terms of online and offline logistics for painting, AGV transports materials from the welding point to the loading point. After manual loading, RFID (Radio Frequency Identification) is used for identification and then sent to different workstations for painting operations. After completion, the materials are directly transported to the assembly AGV for assembly. Compared to manual forklift transportation, the production time has been reduced from 30 minutes to 9 minutes; After adopting robot automatic powder spraying, the production time has been shortened from 30 minutes to 18 minutes, and the number of operators has been reduced from 4 to 1, with better stability than manual spraying.
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