Global Lighthouse Network

Our Lighthouses

Lighthouses are manufacturers showing leadership in applying 4IR technologies at scale to drive step-change financial, operational and sustainability improvements by transforming factories, value chains and business models.

The Global Lighthouse Network is comprised of 238 Lighthouses

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Learn from the network

Access to learn more about the change stories, technologies and enablers behind each Lighthouse transformation.

Meet all our Lighthouses

Explore the organizations who are a part of the Global Lighthouse Network below. Learn how these organizations are contributing to the initiative.

Facing higher cost pressures as well as quality and green production expectations from the international market, Hengtong Alpha accelerated the large-scale application of advanced analytics, machine vision and AI technology across 27 advanced use cases covering the whole production value chain. As a result, unit manufacturing costs have decreased by 21%, the defect rate has reduced by 52% and unit power consumption has fallen by 33%.
People's Republic of China | Technology
Hengtong Alpha Optic-Electric - Suzhou
The rapid development of AI foundation models has brought an explosion in demand for computing power and higher efficiency, quality and iteration speed requirements for AI servers. By deploying AI use cases across order forecasting, warehouse and production scheduling, product design, quality and assembly-testing domains, Foxconn Industrial Internet’s Taiwan factory has achieved a 73% increase in production efficiency, a 97% reduction in product defects, a 21% reduction in lead time and a 39% decrease in unit manufacturing costs.
Taiwan, China
Ingrasys - Taoyuan
The climate crisis has caused significant water supply concerns, as heatwaves and heavy rains create more volatile and turbid supplies. To address this, K-water launched a next-generation AI water treatment plant to reduce production costs, improve responsiveness and reduce human error. It is being scaled across 40+ other sites and has helped K-water to reduce its chemical usage by 19%, improve labour efficiency by 42% and reduce power consumption by 10%.
Republic of Korea | Energy & utilities
K-Water - Hwaseong
Driven by the desire to reduce costs, improve quality and shorten the lead time on solar modules, the Jiaxing site implemented more than 30 Fourth Industrial Revolution use cases, using AI and advanced analytics to boost manufacturing operations. These efforts have had significant impacts, with the site achieving a 28% reduction in unit manufacturing costs, a 43% cut in yield loss and an 84% decrease in production lead time within one year, while also lowering energy consumption by 20%.
People's Republic of China | Energy Technologies
LONGi Solar - Jiaxing
Embracing sustainability ambition from both Mondelēz Global and Beijing City while meeting Mondelēz’s growth ambitions and addressing operating cost pressures due to year-on-year (YoY) 6% labour cost inflation, Mondelēz Beijing implemented 38 Fourth Industrial Revolution use cases, such as an AI-powered dough-making lights-off workshop and gas consumption optimization by machine learning. As a result, Mondelēz Beijing has achieved a 28% net revenue growth and 53% increase in labour productivity while reducing GHG emissions by 24% and food waste by 29%.
People's Republic of China | Food & Retail
Mondelēz - Beijing
To maximize productivity, streamline costs and redeploy the existing workforce to help in-source operations and maintenance (O&M) capabilities, renewable energy company ReNew built on and scaled the digital and analytics backbone from its first Lighthouse site, including new proprietary AI models and the rapid scaling of Fourth Industrial Revolution use cases across 70 wind farms, 10 original equipment manufacturers (OEMs) and 22 unique wind turbine models. Ratlam, the company’s benchmark site for this scale transformation, has sustained improvements of 1.7% higher energy yield, 17% reductions in operating expenses and 40% less waste. This led to a 20% increase in profitability.
India | Energy & utilities, Energy Technologies
ReNew - Ratlam
Increased energy prices and inflation have affected energy costs and the labour-intensive ceramic tile production process. To sustain competitiveness while responding to higher demands and maintaining a complex portfolio of 4,200+ SKUs, VitrA Karo’s Bozüyük site deployed its digital transformation roadmap, focusing on intelligent process and production controls. This has resulted in a 19% increase in OEE, a 56% decrease in scrap, a 14% decrease in energy consumption and a 43% increase in the use of recycled content.
Türkiye | Materials
VitrA Karo - Bozüyük
Facing a growing e-commerce market and driven by retail promotions and a consumer consumption switch from offline to online orders, in addition to heavy seasonality impacts, DHL Supply Chain in Memphis, Tennessee established a strategic Fourth Industrial Revolution site, equipped with a control tower for centralized planning and execution oversight to manage and control E2E operations. This site has seamlessly integrated robots, analytics and a flexible staffing solution, resulting in a 50% overtime reduction, a 57% shipment cycle time reduction and a 290% increase in capacity, leading to a 28% compound annual growth rate (CAGR) since 2019. Consequently, the site has emerged as a primary training hub for the global adoption of new technologies.
USA | Supply Chain & Transportation
DHL Supply Chain - Memphis
To stay ahead of the industry on cost and address common problems of unprofessional and delayed services in the home-appliance industry, Haier deployed 136 Fourth Industrial Revolution use cases for procurement cost savings and improvements in productivity and quality of services, using technologies including 5.5G, advanced algorithms and ready-to-use digital twins. This initiative has resulted in product cost being optimized by 32%, labour productivity increasing by 36% and the service complaint rate being cut by 85%.
People's Republic of China
Haier - Qingdao
To improve agility and responsiveness, raise quality standards and enhance competitiveness, Johnson & Johnson Xi’an replaced its manual facility with a Fourth Industrial Revolution-enabled new factory in 2019. This facility includes digital twins for technology transfer and material handling, intelligent automation of continued process verification (CPV) and batch execution processes. This has shortened the product transfer time by 64% during site relocation and has enabled a 60% decrease in non-conformance, while improving productivity by 40%, operating costs by 24% and GHG emissions by 26%.
People's Republic of China
Johnson & Johnson - Xi’an
To keep up with the growth in e-commerce, faster speed to market and the fluctuating demands that come from increased cost competitiveness, Kenvue Shanghai deployed more than 25 Fourth Industrial Revolution use cases, including big data analytics on social media, digital twins, additive manufacturing and ML across its E2E value chain. This resulted in a 50% reduction in new product introduction lead times, 1.3-times improvement in forecast accuracy and 99.8% on-time-in-full deliveries within 48 hours. This enabled the e-commerce business to double from 30% to 60% of overall business.
People's Republic of China
Kenvue - Shanghai
To improve agility and cater to diverse product segments, reduce costs in an inflationary environment and improve sustainability, Unilever Sonepat implemented 30+ Fourth Industrial Revolution use cases in its E2E supply chain. Top use cases included boiler and spray dryer process twins, as well as customer data-informed no-touch production planning and inventory optimization. This improved service by 18%, forecast accuracy by 53%, conversion cost by 40% and Scope 1 carbon footprint by 88%. The use of biofuels enabled by a boiler process twin also supports livelihoods for local farmers.
India | Food & agriculture, Food & Retail
Unilever - Sonepat
To address growing energy demands while reducing its environmental impact, Johnson & Johnson Xi’an constructed a state-of-the-art manufacturing site. To meet and surpass its LEED Gold® certification, it implemented a series of Fourth Industrial Revolution technologies, including AI algorithms for process control, IIoT-based intelligent cleaning and digital twins. This has resulted in a 47% reduction in material waste, a 26% decrease in GHG emissions and a 23% reduction in energy consumption.
People's Republic of China | Health
Johnson & Johnson - Xi’an - Sustainability
Kenvue Thailand deployed Fourth Industrial Revolution technologies for more sustainable resource management across site operations. This includes an end-to-end water-to-ecosystem performance management system, a digital twin to optimize chiller system energy consumption, and a dynamic scheduling and container loading optimization solution that leverages data analytics and robotic process automation. From 2018 to 2023, the site reduced water utility intake by 35%, energy-related consumption (scope 1&2) by 34%, correlating GHG emissions by 29%, normalized for production volumes, and container utilization improved by 35% leading to more efficient transportation.
Thailand | Health
Kenvue - Bangkok - Sustainability
Schneider Electric’s Hyderabad site aims to be zero carbon on Scope 1 and 2 by 2030, based on a strong Fourth Industrial Revolution core. This includes an E2E closed-loop system with CO2 tracking for strategic suppliers. The system is powered by real-time data generation and cloud analytics for all facility assets that interlink with shop-floor operations using an IIoT-enabled equalizer and AI-based predictive monitoring. This has led to a 59% reduction in energy consumption, 61% decrease in CO2 emissions, 57% cut in water consumption and a 64% reduction in normalized waste generation.
India | Technology
Schneider Electric - Hyderabad - Sustainability
To become a zero-carbon pioneer in the context of 92% growth in production output in the past three years, Siemens’ Chengdu factory deployed a holistic digital energy management system, implemented predictive maintenance throughout the manufacturing process, introduced AI-based automation to identify and handle up to 16 types of production waste and applied eco-design features to improve circularity and dematerialization. This has reduced unit product energy consumption by 24% and production waste by 48%.
People's Republic of China | Technology
Siemens - Chengdu - Sustainability
To build resilience in the face of rising energy costs and also reduce carbon emissions, Haier applied big data and AI to establish a power load model of equipment, as well as a production scheduler optimizing for energy consumption, reducing energy consumption by 35% and GHG emissions by 36%.
People's Republic of China | Technology
Haier - Tianjin - Sustainability
To reach its net zero target already by 2026, four years ahead of the corporate pledge, Siemens adopted digital process analysis and measurements, reducing its scope 1 & 2 GHG emissions by 69% normalized to volumes. In addition, to decarbonize its entire supply chain (scope 3), the plant acts as an incubator to develop Fourth Industrial Revolution products such as a digital product pass and a blockchain-based software to exchange CO2 data with suppliers.
Germany | Technology
Siemens - Amberg - Sustainability
With an aim of reducing energy use, water consumption, and GHG emissions, Flex’s facility in Sorocaba implemented smart factory utilities management and optimized electronic waste in its supply chain and manufacturing operations using IoT sensors to enable circular economy solutions. Flex Sorocaba reduced scope 1 & 2 GHG emissions by 41%, for scope 3 managed to avoid 44 kilotonnes of CO2 eq (carbon dioxide equivalent), and reduced water consumption by more than 30%.
Brazil | Technology
Flex - Sorocaba - Sustainability
Facing the demand of customers for customized design, fast delivery and high quality, Haier refrigerator factory leverages big data, digital twin and advanced visual inspection technology to accelerate R&D, upgrade manufacturing process and logistics scheduling mode . The order response lead time has been shortened by 35%, production efficiency has been increased by 35% and quality performance has been improved by 36%.
People's Republic of China | Other
Haier - Qingdao / Refrigerators

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