LG Electronics, formerly Lucky-Goldstar, is one of South Korea’s largest and most globally recognised engineering powerhouses.
A household name for decades, LG has built a reputation through its expansive portfolio of consumer appliances – from televisions and refrigerators to washing machines and air conditioners.
But behind the scenes, LG is also rapidly becoming a serious force in industrial and service robotics, with ambitions that stretch well beyond your kitchen or laundry room.
As automation and artificial intelligence reshape the manufacturing landscape, LG has positioned itself at the forefront of this transformation.
LG’s robotics efforts are centred within its Production Engineering Research Institute (PRI) and Smart Factory Business Division, which together drive innovation in areas like autonomous logistics, AI-based inspection, predictive maintenance, and digital twins.
These technologies are not just experimental – they are already fully operational in LG’s next-generation factories, such as the “Lighthouse Factory” in Clarksville, Tennessee.
What makes LG unique in the robotics space is its proven ability to scale. If robotics truly make the leap into everyday consumer life, as many predict, then companies with vast experience in manufacturing reliable, mass-market hardware will have a major advantage.
LG already ships millions of appliances every year; integrating robots into this ecosystem is a natural progression.
In the same way that LG dominates categories like washing machines and smart TVs, it could just as easily become a dominant supplier of domestic robots – from AI-enabled cleaning bots to intelligent kitchen assistants.
In this exclusive Q&A with Robotics and Automation News, two senior LG executives – Song Si-yong and Charles Lonergan – discuss how the company is using robotics and smart automation to revolutionise its manufacturing operations, and how these same innovations may soon shape the homes of the future.
Responses from:
- Song Si-yong, head of smart factory business division, Production Engineering Research Institute, LG Electronics
- Charles Lonergan, director of manufacturing, LG Electronics
Robotics & Automation News: What are the main robotics and automation technologies in LG’s Clarksville “Lighthouse Factory”? How do the 5G-enabled robots and autonomous logistics systems improve efficiency?
Charles Lonergan: LG’s “Lighthouse Factory” in Clarksville, TN leverages robotic and automation technologies to enhance efficiency and output across its smart manufacturing lines of front-load and top-load washing machines and dryers.
Among this technology is a Citizens Broadband Radio Service (CBRS)-based private 5G network, which provides the high-speed, low-latency connectivity necessary for real-time communication among thousands of connected machines, sensors, and automated vehicles.
This network supports over 200 autonomous guided vehicles (AGVs) and autonomous mobile robots (AMRs) that autonomously navigate the factory floor using QR codes and LiDAR sensors, safely transporting materials and equipment. This frees up workers to focus on higher-value tasks.
Additionally, robotics are deployed for complex or hazardous operations, such as heavy lifting and welding, maximizing safety and precision. Together, these systems enable the factory to produce a new appliance every 13 seconds.
R&AN: How is AI used in quality inspection for washing machines and dryers? What improvements in defect rates or consistency have you seen?
Charles Lonergan: AI is deeply integrated into LG’s quality inspection processes. A six-camera vision system enhanced with AI technology compares each assembled unit to a master sample in real time, identifying misalignments.
If any inconsistency is detected the line is stopped and the unit is flagged for human inspection. This is the case for water leak testing, function checks, noise testing, and visual inspection – all critical connection points for LG’s products.
R&AN: What are the core components of LG’s smart factory strategy for external clients? Can you share examples of successful deployments outside LG facilities?
Song Si-yong: LG’s smart factory solution strategy is deeply rooted in intelligent manufacturing optimization, extending far beyond the mere delivery of machinery.
Rather, LG prioritizes the establishment of strategic partnerships with clients, tailoring solutions to their unique needs and objectives to deliver a customized, customer-focused approach.
This commitment includes comprehensive end-to-end support, encompassing factory design, process audits, ROI analysis, and the development of phased implementation roadmaps.
In terms of hardware solutions, LG provides a range of automation technologies such as robot-based assembly automation, AI-based inspection solutions, and intelligent logistics automation solutions.
Additionally, LGE offers integrated SW solutions that can manage everything from equipment data collection to management systems.
These solutions include automated production and quality control functions that link order, production, and logistics, ensuring maximum productivity across all areas of production operations.
With a strong in-house R&D capability, LG can customize solutions to meet the specific needs of customers, enabling rapid optimization of their production capabilities.
For example, LG has supplied logistics automation solutions to an automotive supplier located in Savannah, Gerorgia, and is currently working with other automotive companies as well.
The solutions include a Manufacturing Control System (MCS) that synchronizes the optimal supply sequence of components required for mixed production across the entire production line.
Additionally, LG is providing factory construction consulting services for a new assembly and processing factory in the United States.
R&AN: What specific advantages does 5G bring to LG’s manufacturing environment, particularly for robots and AGVs?
Charles Lonergan: The private 5G network installed in the second half of 2023 at LG’s Clarksville factory enables ultra-low latency and highly reliable connectivity between the factory’s machines, sensors, and more than 200 autonomous vehicles, ensuring precise coordination and operation.
This level of connectivity is especially vital for the safe and efficient navigation of AGVs and AMRs, and for real-time data exchange across production steps.
R&AN: What AI-powered robotics or automation solutions has LG’s Production Engineering Research Institute developed, and what impact have they had?
Song Si-yong: LG employs AI solutions to keep the production lines running without interruption and enhance product quality. Key solutions include:
- Predictive Maintenance: The sensing systems monitor the condition of production equipment, while the AI engine analyzes the data to identify components that require attention during maintenance, informing operators and technicians of specific check points.
- Digital Twin: This solution enables real-time monitoring of logistics flow and material supply while simulating field conditions for the next 10 minutes at 30-second intervals. The system proactively alerts operators and engineers via mobile messages if material supply delays are anticipated. It predicts Work In Progress (WIP) shortages, anticipates deadlocks during model changes, and facilitates adjustments to the operational logic of the logistics system. Additionally, its playback mode allows for the reproduction of issues, contributing to the establishment of modified operational processes that prevent similar challenges in the future.
- Inspection: The AI engine implemented in the inspection system automatically detects defects by learning various types of defects.
- Automatic Calibration: an AI engine is applied to the equipment control system to monitor real-time changes in product quality and automatically adjust process parameters related to quality variations.
LG can provide these cutting-edge technologies, tailored to meet customer needs through its robust R&D capabilities.
R&AN: What tasks do the 166 AGVs in Clarksville perform? How autonomous are they, and what are the plans for expanding the system with AMRs?
Charles Lonergan: The 166 AGVs at LG’s Clarksville factory perform a range of autonomous logistics tasks, including transporting parts and materials between production cells and interfacing with elevators for vertical transport.
These AGVs navigate using about 20,000 QR codes placed on the floor and are equipped with sensors to avoid obstacles and ensure safe movement around workers.
In addition to AGVs, the facility uses AMRs equipped with front and rear LiDAR sensors for enhanced navigation capabilities.
Battery management is fully automated, with robots replacing AGV batteries proactively. In the future, LG will look to expand this system with additional AMRs to benefit factory operations.
R&AN: How is LG using its manufacturing data and patent portfolio to improve robotics and automation? Are machine learning models used to optimise performance or predict failures?
Song Si-yong and Charles Lonergan: LG’s extensive manufacturing data, combined with over 1,000 smart factory patents, is a foundational asset in advancing both internal operations and external B2B offerings.
Manufacturing data powers machine learning algorithms that optimize robotic performance, predict maintenance needs, and reduce unplanned downtime.
For example, in a factory, data from various sensors and operational information are collected and monitored in real-time.
An operational system, trained on a model based on historical data, can anticipate signs of abnormal conditions and take preventive measures to avoid such situations.
However, in the event of unexpected equipment stoppages, the solution analyzes the operational data and alarm situations of the equipment, matches this data with accumulated historical information, and presents the optimal response plan to the operator, enabling rapid recovery.
AI models embedded in quality inspection systems and digital twins use this data to refine production processes, identify inefficiencies, and enable real-time decision-making.
These technologies are packaged and offered to other manufacturers as part of LG’s growing smart factory solutions portfolio.
R&AN: What are LG’s key robotics and automation goals over the next 3-5 years, both internally and for the broader market?
Song Si-yong: LG is scaling its smart factory solutions across diverse industries, from electronics, batteries and automotive components to semiconductors, and heavy machinery, with further expansion into high-potential sectors like pharmaceuticals, cosmetics and food&beverages.
The company is managing full-scale, turnkey smart factory projects across the US and Southeast Asia, aiming to enhance efficiency, improve quality, and boost competitiveness for its clients.
LG projects orders for these solutions to reach $300 million in the current year, with anticipated growth exceeding $750 million by 2030.
LG’s approach to smart factories prioritizes smart strategies tailored to individual customer needs, emphasizing agility, resilience, and future-readiness over mere automation.
The company is committed to collaborating with partners to develop operations that are not only more efficient but also more competitive and sustainable.
LG aims to lead the evolution of the manufacturing sector by co-creating the future of intelligent production.
R&AN: Are there any specific technologies or trends LG is focusing on for future investment?
Charles Lonergan: LG continues to monitor the convergence of AI and robotics, the evolution of 5G as an enabler of real-time factory communication, and increased demand for sustainable and resilient manufacturing systems.
LG will continue to invest in its manufacturing capabilities to benefit its global customer base.
