[On the Job] A Day With Charles Lonergan, Manufacturing Director at LG’s Tennessee Smart Factory
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By News Reporter
Serious About Sustainability, Company Introduces New Material and Production
Process to Minimize Environmental Impact
SEOUL, Aug. 18, 2025 — LG Electronics (LG) is reducing plastic consumption and carbon emissions by adopting a new material and manufacturing process for its commercial 4-way system air conditioners. Aligned with the company’s Better Life for All ESG vision, these latest efforts demonstrate an unwavering commitment to minimizing environmental impacts.
TÜV Rheinland, a global testing and certification organization, recently confirmed that LG’s newly instituted production process has lowered carbon emissions from the manufacturing of its 4-way system air conditioners to 14.85 kilograms of CO₂ equivalents* per unit. Along with the shift in manufacturing method, the primary driver of this reduction is the introduction of a new material used for the air conditioners’ exterior panels.
Moving away from conventional plastic manufacturing techniques, LG employs a foaming injection molding process whereby nitrogen gas is injected into the mold to create bubbles within the material. This innovative approach reduces plastic use by approximately 900 grams per unit. Additionally, LG has replaced the use of Acrylonitrile Butadiene Styrene (ABS) with Polypropylene (PP), which has a lower carbon footprint.
These improvements are expected to cut plastic consumption by roughly 270 tons annually and CO₂ equivalent carbon emissions by over 4,400 tons each year – a reduction comparable to the carbon absorbed in one year by a 30-year-old pine forest covering more than 580 soccer fields.
LG began applying its foaming injection molding method to 4-way system air conditioners in June and plans to gradually expand it to other residential and commercial models.
In pursuit of carbon neutrality, LG aims to reduce greenhouse gas emissions by 54.6 percent by 2030 compared to 2017 levels, as outlined in its Sustainability Report. To reach this target, the company is integrating high-efficiency equipment into its manufacturing processes and adopting renewable energy sources to produce high-efficiency appliances leveraging its proprietary Core Tech.
A prime example of Core Tech is LG’s inverter motor technology, which minimizes energy waste by adjusting motor and compressor speeds in real time according to demand. The company has also advanced its environmental compliance by launching an inverter scroll chiller using R32 refrigerant, which has a Global Warming Potential (GWP) about 30 percent lower than R410A refrigerant.
“The new material and manufacturing process we’ve introduced for our 4-way system air conditioner underscored our efforts to minimizing environmental impacts,” said Bae Cheung-hyun, head of the System Air Conditioners Business at the LG ES Company. “LG will continue to leverage innovative technologies to develop eco-conscious air conditioners for a healthier planet.”
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* A metric measure used to compare the emissions from various greenhouse gases on the basis of their global-warming potential (GWP), by converting amounts of other gases to the equivalent amount of carbon dioxide with the same global warming potential.
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By News Reporter
In this interview, we delve into the creative process of Fred Scott, the London-based BAFTA-winning filmmaker, as he brings LG’s “Radio Optimism” campaign to life. This campaign aims to strengthen meaningful human connections in a world dominated by superficial interactions on social media.
What does it mean to genuinely connect in a hyper-connected era, where people paradoxically feel more disconnected than ever? To strengthen meaningful human connections in a world dominated by superficial interactions on social media, LG launched a new brand campaign called “Radio Optimism” last month, expanding its “Life’s Good” philosophy into the digital space through shared musical experiences.
To create the brand film for the campaign, LG collaborated with Fred Scott, a London-based BAFTA-winning filmmaker known for “London Bridge: Facing Terror.” With a foundation of emotionally grounded, human-centered storytelling, Scott brought his unique creative lens to the project and crafted a short documentary film that highlights the power of music to bridge even the widest emotional and physical distances.
In this piece, we delve into Scott’s creative process – tracing how he creatively brought the message of “Connecting the Disconnected” to life for the campaign through his distinctive storytelling.
What do you value most as a filmmaker and a creator? What drives your creative process?
Authenticity (obviously), intimacy and a clear sense of openness and trust is what I am always seeking when making a film. I believe in the power of narrative to foster empathy and build shared understanding. How can I connect with audiences without authenticity or real people?
Whenever I start a project, I actively seek out genuine individuals and stories, whether a reclusive filmmaker reflecting on their art or people searching for redemption after a traumatic event. My aim as a creator is to bring these stories to life authentically – in an environment where the subjects feel protected and supported.
What did you think when you first heard about “Radio Optimism?” Was there something about the idea that resonated with you creatively or personally?
The concept of togetherness and connection in the Radio Optimism campaign resonated with me, especially as we live in a world where we’re supposedly never more connected – yet we can often feel disconnected.
Through this campaign, LG is bridging the gap between technology and emotional connection in a powerful, effective and, most importantly, genuine way. It makes those who feel disconnected feel part of a community.
What also stood out was the longevity of the platform. It’s not just a fleeting story but a campaign that could grow into a movement. Through the universal language of music, Radio Optimism has the power to be inclusive, creating something that anyone around the world can contribute to.
How did you choose the subject for the film?
Finding the right person with an inspiring story to tell and who lives or works for periods away in a remote location was no mean feat. However, when we found Ann Eileen, everything just clicked into place, and I knew she encapsulated everything I wanted the brand film to live and breathe.
She truly is the beacon of the film. She’s effervescent, relatable, approachable and deeply inspiring. She has sacrificed a lot to pursue her passion in her field of research to protect the planet but at the cost of spending more than three months away from her family. Yet, despite the time apart, they’ve found ways to connect, and it’s truly inspiring to see how Ann Eileen’s values and ethics can be witnessed in her children.
Through the film, I wanted to capture this genuine, nurturing and intimate feeling of Ann’s family life and highlight the power of meaningful connections.
Tell us more about your creative process for the short documentary film?
For this project, my approach leaned into a documentary style with a particular eye on scale, juxtaposing the intimacy of Ann Eileen’s family life with the epic, remote and expansive landscape around her.
I wanted to find moments of genuine, emotional connection within a story of isolation while keeping the tone soulful rather than sugary.
The cinematography was designed to feel authentic and beautiful, highlighting both the uniqueness of the setting and the realism of the experience. The story’s authenticity is key to connecting with the audience. Inauthenticity breaks that bond.
How do you stay connected with your family when you are divided by distance?
Staying connected with my family while away has always been important to me. I use video calls, voice notes and sometimes even analogue ways, such as leaving notes. Whilst technology offers us ways to communicate, leaving notes is a very personal way of sharing emotional connection.
I’m fortunate to be a parent, and if I were to make a song using the Radio Optimism platform, I’d make one for my four-year-old son. He is obsessed with the saxophone and discovering language, so this would be a fun way to capture this precious moment of his childhood.
What do you want audiences to feel when they watch the Radio Optimism documentary film?
I hope the authenticity of the film resonates with people. Ann Eileen’s life may be unique, but the emotions and relationships at the heart of it are something we all recognize.
I’d love for the film to encourage people to keep communicating and strengthen their relationships, especially in a world where it’s easy to drift apart.
Sometimes, we need a little nudge to make a phone call or create something for someone we care about—I want this film to feel like that nudge.
I also want the audience to see the joy and emotional power of creating a personalized song, even if it’s about something silly and every day like embarrassing knitwear.
What are your reflections on the production and what does “Life’s Good” mean to you?
The whole process was incredibly satisfying because it felt genuine, collaborative and driven by a shared purpose to put something meaningful into the world.
I feel the film captured the kind of optimism and authenticity we hoped to share with audiences.
To me, “Life’s Good” means having purpose, hope and shared experiences. I feel fortunate that my work allows me to support others and tell stories that matter.
Watch the film
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By News Reporter
Manufacturing has been a cornerstone of global economic growth since the Industrial Revolution. Today, however, the landscape is undergoing a fundamental transformation. Societal and structural shifts – including aging populations, shrinking labor forces, evolving trade policies and overhauled supply chains – are pushing the industry to rethink how products are made.
This isn’t merely a phase of incremental improvement. It’s a turning point, one where the traditional manufacturing model is being reimagined. Forward-thinking companies are embracing next-generation production systems such as gigafactories – vast, automated operations – and dark factories, which can function with minimal or no human intervention.
The momentum is already visible in the numbers. According to
link hidden, please login to view, the global smart factory market, valued at USD 155.6 billion in 2024, is expected to more than double to USD 386.4 billion by 2034. With a projected CAGR of 9.5 percent, the smart factory is fast becoming the new foundation of industrial competitiveness.
LG’s Vision for Smart Factories
With over 60 manufacturing sites across more than 40 countries, LG has a long and storied history in global production. Building on nearly 70 years of expertise, we launched our smart factory solution business in 2024 to lead this new industrial revolution.
Our approach is rooted in intelligent manufacturing optimization. We go beyond delivering machinery – we form strategic partnerships. Our solutions are built around the specific needs and goals of each client, ensuring a tailored, customer-first approach.
A Strategic Partner in Manufacturing Transformation
In today’s dynamic manufacturing environment, smart factory solutions are no longer optional – they’re essential. LG offers end-to-end support, from factory design and process audits to ROI analysis and phased implementation roadmaps.
We serve a diverse range of customers, from small manufacturers starting their digital journey to large enterprises modernizing complex operations. Every engagement begins with a deep analysis of industry requirements, production volumes and existing infrastructure – enabling us to craft highly customized solutions.
AI-Powered, Data-Driven Manufacturing
At the core of LG’s smart factory capabilities is a robust platform powered by approximately 770 terabytes of production data. Leveraging AI and big data analytics, our systems transform conventional operations into intelligent, adaptive ecosystems.
Through digital twin technology, we simulate factory layouts and processes before physical implementation, reducing risk and eliminating guesswork. Generative AI monitors equipment in real time, identifying issues like unusual vibrations and recommending corrective actions. Vision AI further enhances operational safety and product quality by detecting defects and safety hazards instantly.
Consider this scenario: a simple voice command – “7 AM: vibration detected on equipment A” – triggers an immediate system diagnosis, referencing historical data and suggesting next steps. Vision AI can then assist the operator in resolving the issue on-site. This real-time, data-driven decision-making is the hallmark of a true smart factory.
Proven Results, Real-World Impact
The results speak for themselves. At LG Smart Park in Changwon, South Korea, automation has reached 65 percent, resulting in a 22 percent increase in productivity and a 30 percent reduction in defects. In the United States, our Tennessee facility achieved a 17 percent boost in productivity and a 30 percent gain in energy efficiency.
Both sites have been recognized as , – a prestigious acknowledgment of excellence in advanced manufacturing.
Scaling Success Across Industries
Building on these successes, we’re expanding our smart factory solutions into new sectors – from batteries and automotive components to semiconductors and heavy machinery. We’re also entering high-potential industries like pharmaceuticals and cosmetics.
Across the U.S. and Southeast Asia, LG is managing full-scale, turnkey projects designed to enhance efficiency, improve quality and increase competitiveness. We expect orders for our smart factory solutions to reach KRW 400 billion this year, with projections exceeding KRW 1 trillion by 2030.
Co-Creating the Future of Manufacturing
At LG, a smart factory isn’t just about high-tech tools – it’s about smart strategies built around our customers. We believe success isn’t defined by how automated a factory is, but by how agile, resilient and future-ready it becomes.
We’re proud to collaborate with our partners to build operations that are not only more efficient, but also more competitive and sustainable. As the manufacturing sector continues to evolve, LG is committed to leading the way – co-creating the future of intelligent production.
By Song Si-yong, head of Smart Factory Business Division, Production engineering Research Institute, LG Electronics
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By News Reporter
New Manufacturing Plant in Sri City Expected to Begin Operations by End of 2026
SRI CITY, Andhra Pradesh, May 8, 2025 – LG Electronics India Ltd. (LGEIL) announced the commencement of construction of its new manufacturing facility in Sri City, Andhra Pradesh today at a ceremony graced by the presence of Shri Nara Lokesh, Hon’ble Minister for Information Technology, Electronics and Communications, Real Time Governance and Human Resources Development, Government of Andhra Pradesh. The new plant is expected to commence operations by the end of 2026.
Strategically located in Sri City’s industrial area, the new manufacturing facility will enhance LGEIL’s production capacity and also enable local employment in the region. The new facility will be LG Electronics’ third plant in India. The other two plants are located in Greater Noida, Uttar Pradesh and Pune, Maharashtra. This investment underscores India’s potential as a critical hub within LG Electronics’ global supply chain.
The government of Andhra Pradesh has approved 247 acres of land in Sri City for LGEIL’s new manufacturing facility, which is expected to generate around 1495 direct jobs. LGEIL plans to invest approximately USD 600 million (INR 5001 crores) over the next four years, with the potential to attract ancillary businesses to the region, thereby creating an ecosystem for white good manufacturing in the state of Andhra Pradesh.
The new plant at Sri City is expected to localize production further and meet the growing demand for LG products throughout India. It will also strengthen LGEIL’s supply chain in South India, while helping expedite access to LG products for consumers in the region. The facility will manufacture a diverse range of products, including AC compressors, refrigerators, washing machines and air conditioners.
In addition to the presence of Shri Nara Lokesh, the ceremony was attended by other senior government functionaries along with senior LG Electronics executives from South Korea, including Lyu Jae-cheol, president of the LG Home Appliance Solution Company; James Lee, president of the LG Eco Solution Company and Hong Ju Jeon, managing director of LGEIL. Other government officials and senior LGEIL leadership were also present at the ceremony.
Sharing his best wishes from Amaravati, the new capital of Andhra Pradesh, Shri N Chandrababu Naidu, Hon’ble Chief Minister of Andhra Pradesh said, “We wholeheartedly welcome LG Electronics to Sri City, Andhra Pradesh. The announcement of LG Electronics’ new manufacturing plant in Andhra Pradesh is a testament to Andhra Pradesh’s progressive policies with regards to being industry friendly, ease-of-doing-business, fostering innovation and being home to world-class manufacturing hubs. A well-developed industrial ecosystem, great connectivity and pro-business environment makes Sri City the best location for the new plant.”
Shri Nara Lokesh, Hon’ble Minister for Information Technology, Electronics and Communications, Real Time Governance and Human Resources Development, Government of Andhra Pradesh said, “We are delighted that LG Electronics has chosen Sri City for its third manufacturing facility in India. This is a testament of LG Electronics’ commitment to India and I am confident that this expansion into Andhra Pradesh will address the potential growth in demand for LG products across India.”
“We are taking yet another important first step toward enhancing our partnership with India and contributing to its economic growth. The construction of our third manufacturing plant will complement our existing production facilities in Noida and Pune and marks a new milestone in our journey in India,” said Lyu. “This brand-new facility will create more jobs and increase local production,” he further added.
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By News Reporter
Company to Leverage Lighthouse Factory Expertise
to Develop Future-Oriented Business Models
SEOUL, July 18, 2024 — LG Electronics (LG) is advancing its smart factory solutions business by integrating artificial intelligence (AI) and digital transformation (DX) with its extensive 66-year history of manufacturing and production expertise.
The Ultimate Fusion of AI and Manufacturing Capabilities
Earlier this year, LG officially entered the smart factory solutions market. The Production engineering Research Institute (PRI), which has been enhancing production and manufacturing competitiveness for LG Group affiliates, is now extending its expertise to external clients. Services offered include production consulting, development of equipment and operation systems and training for technology personnel.
Despite being in its inaugural year, the business has already achieved significant milestones. PRI anticipates securing orders worth approximately KRW 200 billion from external clients for its smart factory solutions.
Major clients include secondary battery manufacturers, automotive parts manufacturers and logistics companies. LG plans to aggressively expand into industries with rapidly growing factory demand, such as semiconductors, pharmaceuticals, biotechnology and food and beverage. The goal is to develop the smart factory solutions business into a multi-trillion KRW enterprise by 2030, excluding revenue generated within the LG Group.
According to market research firm
link hidden, please login to view, the global smart factory market is projected to grow from USD 155.61 billion this year to USD 268.46 billion by 2030. 770TB of Manufacturing Data and Over 1,000 Patents
LG has accumulated vast amounts of manufacturing data and know-how through 66 years of factory design, construction and operation. In the past decade alone, the company has amassed 770 terabytes (TB) of manufacturing and production data, equivalent to storing approximately 197,000 high-definition movies (assuming each movie is 4GB). The company’s competitive edge also lies in its various core production technologies essential for smart factory configuration, with PRI filing over 1,000 patents related to smart factory solutions. LG aims to set its smart factory solutions apart by integrating its extensive manufacturing data and expertise with AI and DX, leveraging world-class production technologies. These smart factory solutions encompass production system design, monitoring and operation through Digital Twin technology; big data and generative AI-based management of quality, industrial safety and equipment; and the provision of various industrial robots.
Production Efficiency Directly Linked to Business Profitability
Smart factory solutions focus on minimizing even the briefest delays or minute errors between processes. Since efficiency in production is directly linked to the overall profitability of the business, enhancing it is crucial. For example, at LG’s refrigerator production line in Changwon, a refrigerator is produced every 13 seconds. A 10-minute delay in the production line would result in a production shortfall of 50 refrigerators. Assuming the price of one refrigerator is KRW 2 million, a 10-minute delay translates to a loss of KRW 100 million.
This impact is even more significant for products with faster production speeds.* Therefore, solutions that minimize delays across processes – from the seamless supply of multiple components to assembly, packaging and inspection – are essential.
Comprehensive Production Solutions Covering the Entire Journey
LG approaches the smart factory business not just as unit solutions for specific areas but as comprehensive solutions covering the entire journey for clients, from factory planning to design, construction and operation. Considering the client’s environment and industry characteristics, the company diagnoses existing factories and identifies areas for improvement, establishing a step-by-step roadmap from automation, informationization and intelligence perspectives to maximize investment effectiveness.
Digital Twin Solution for All Value Chain
The production system design and operation solutions leverage real-time simulations using Digital Twin technology. Before the factory is built, a virtual replica identical to the real factory is created, allowing clients to preview the production and logistics flow. This enables optimal efficiency in factory design.
During the operational phase, analyzing real-time data helps detect bottlenecks, defects and malfunctions in the production line in advance, thereby contributing to productivity improvement.
Autonomous Mobile Robots and Collaborative Robots
LG’s various industrial robot solutions for factory automation offer significant advantages. The Autonomous Mobile Robot (AMR) is equipped with cameras, radar and LiDAR sensors to recognize its surroundings and supply parts and materials. It navigates effectively, avoiding workers and obstacles through autonomous driving.
The Mobile Manipulator (MM), which combines a multi-joint robotic arm with an AMR, can automate a range of tasks seamlessly. It is capable of diverse actions such as assembly, defect inspection and transporting parts and materials. Additionally, it can replace the batteries of nearby AMRs when they run low.
Generative AI Solutions for Easy Anomaly Diagnosis
Solutions that assist in managing yield rates and ensuring the smooth operation of equipment are also highly beneficial. Sensors installed throughout the factory detect abnormal signals such as vibrations and noise caused by equipment aging or lack of lubrication. Big data is then used to determine the causes and recommend corrective actions.
Generative AI based on large language models allows for easy use through voice commands. For example, saying “abnormal vibration in equipment A at 2 p.m.” records the abnormal signal on the server. A command like “show recent abnormal vibrations and corrective actions” provides a list of defect types and previous corrective actions in order of likelihood.
Additionally, LG has developed a real-time detection system powered by Vision AI. This system learns the factory’s normal operating conditions and detects anomalies such as temperature fluctuations and defects. It also enhances factory safety management by identifying workers who are not properly wearing safety helmets or work vests.
Expediting the Development of a Future-Oriented Business Model by Harnessing Lighthouse Factory Expertise
LG’s intelligent autonomous factories in Changwon, South Korea, and Tennessee, USA, have been recognized as Lighthouse Factories by the World Economic Forum. Following the implementation of smart factory solutions, productivity at the Changwon plant increased by 17 percent, energy efficiency improved by 30 percent, and quality costs due to defects were reduced by 70 percent. Within the LG Group, production facilities at over 60 locations in 40 regions worldwide are applying solutions from PRI.
Leveraging this internally and externally validated smart factory expertise for business ventures holds significant meaning in terms of commercializing intangible assets. LG is driving a transformation of its business portfolio, which has traditionally focused on production of hardware, by integrating software and solutions into a future-oriented structure. This approach is expected to significantly contribute to the rapid growth of the company’s B2B sector, one of the three key growth drivers in LG’s 2030 Future Vision, especially as it targets numerous external corporate clients.
“We will offer optimal smart factory solutions at every stage – from planning and design to construction and operation – becoming the ideal partner that supports our clients throughout their entire production journey,” said Jeong Dae-hwa, head of LG PRI.
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* Unit for production speed is parts per million (PPM).
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