Hongrita & HKPC

Hongrita is a leading manufacturer of plastic molds and precision components, dedicated to providing high-quality molding solutions for global clients. The Hong Kong Productivity Council (HKPC), a recognized authority in driving industrial innovation and technology adoption, has long committed to assisting businesses in achieving digitalization and intelligent upgrades.
Faced with challenges such as labor shortages, unstable production, and data opacity common in traditional manufacturing, Hongrita has partnered with HKPC to drive digital and intelligent transformation. By introducing a self-developed Digital Management System (DMS) and integrating core Industry 4.0 technologies such as IIoT, AI algorithms, and 5G networks, they have optimized production processes and equipment management. The Industry 4.0 project has successfully created a highly efficient, automated Smart Factory, achieving end-to-end digitalization and green operations.

The award-winning Industry 4.0 solution incorporates key elements for achieving efficient production and operational excellence.

Developed the Digital Management System (DMS), integrating MES, APS, WMS, and QMS core modules to enable real-time production monitoring, data flow, and end-to-end process optimization. Incorporated a BI data analytics platform to visualize operational data and support precise decision-making.

Developed flexible production lines integrated with automated equipment and AGV smart logistics systems, enabling fully automated processes from raw material transport to final product warehousing. An APS (Automatic Production Scheduling), which uses historical data to match the optimal production plan, is enhancing production flexibility and efficiency.

Applied an AI-powered quality prediction system, leveraging visual inspections and real-time production parameters to anticipate quality issues and issue alerts, ensuring product stability. A tool lifespan prediction system combines ultrasonic, vibration sensors, and AI models to preemptively identify equipment anomalies and reduce downtime.

The award winner installed an energy and CO₂ management platform to monitor and analyze energy consumption in production in real time. This enabled it to optimize the use of water, electricity and gas and reduce its CO₂ emissions.
The plant also carried out technical upgrades, including a modernization of the central compressed air station. It also harmonized its power supply, photovoltaic energy generation, cold water storage systems, magnetic levitation air conditioning systems and closed cooling water systems. These measures led to significant annual savings in electricity costs and a CO₂ reduction of 1,538 tons.