Hanlim Rodex, a concrete pedestrian block factory located on the outskirts of Gongju, Chungnam. Just a year ago, it was a place where working without a mask was difficult due to dust and noise, and daily production quantities had to be confirmed on paper the next day. But now, it has transformed into a smart factory where real-time data appears on monitors and an unmanned shipping room operates.

Workers share changes in processes in real-time, come up with improvement ideas, and implement them directly. Hanlim Rodex is still continuing its 'ongoing innovation'. Hanlim Rodex is a small to medium-sized enterprise primarily producing pedestrian blocks (95%) and grass blocks (4%). It is specialized in the public procurement market, with 99% of its supply to the Public Procurement Service. Established in 2006, it is a small but solid company with 26 employees and an annual revenue nearing 10 billion won. It mainly supplies to public works sites such as parks, sidewalks, and government institutions, including the Sejong Government Complex. Its market share in the domestic pedestrian block market is around 30%.

Hanlim Rodex became interested in the smart factory project to obtain certification for quality-assured procurement items from the Public Procurement Service. What began as an innovation activity with expectations for quality improvement resulted in a near 'factory transformation'. During the 7 weeks that three Samsung Electronics smart factory mentors stayed at the factory, a total of 70 improvement tasks were identified and implemented.



The most noticeable change is the reduction in mold replacement time. The mold is a key piece of equipment that shapes the concrete blocks and determines the specifications and design of the products. Previously, it took 60 minutes to replace, but now it has been reduced to 20 minutes. The production of pedestrian blocks per hour increased from 31 to 93, tripling the output. The indoor storage space expanded from 101 pyeong to 303 pyeong, and by installing solar panels on the factory roof, annual electricity costs were reduced by 120 million won. The previously inefficient structures in the aggregate input, transfer rails, pigment measurement, and finished product packaging processes were completely improved.

Previously, the outdoor road was unpaved, making it difficult to input aggregates. The input port was bent, and there was a risk of wall collapse. The pigment input was difficult to measure accurately, and during the loading of blocks after curing, frequent stoppages occurred due to poor horizontal alignment of the transfer rails. In the packaging process, rainwater accumulated, and packaging materials mixed with waste, leading to poor organization.

Unused equipment was left unattended, and the criteria for loading finished products were unclear, resulting in significant space waste. When loading blocks, misalignment was frequent, and workers experienced high fatigue due to dust, noise, and repetitive tasks. Such a backward environment inevitably had a negative impact on both production efficiency and product quality.

However, after the improvement work, the most noticeable change was in quality.

By changing the pigment input method, the input time was reduced from 60 seconds to 10 seconds. The defect rate for block indentation dropped to half. Mold replacement is now carried out according to standardized procedures within designated maintenance areas, and the replacement of aging binder rollers and maintenance of fixed axes were also conducted. The space secured by removing unused equipment and organizing the storage area increased work efficiency, and the packaging of finished products, which previously used wooden pallets, was changed to plastic material to enhance durability.

The digital transformation of factory operations is also progressing rapidly. With the introduction of the Manufacturing Execution System (MES), the method of checking yesterday's production quantity today has changed to a real-time monitoring system. Shipping vehicles can now automatically print invoices by simply entering the vehicle number at an unmanned kiosk, and the location of the shipped products can be checked at a glance. As paper-based work decreases, information accessibility and management efficiency have significantly improved. The internal shipping process has been automated without the need to visit the office, and the shipping personnel can now provide real-time guidance on loading locations.

Kim Tae-hyung, CEO of Hanlim Rodex, said, "The employees' response that the factory has become cleaner is the most memorable," and expressed hope that "with the procurement certification, the trust in our products will increase, leading to improved work efficiency and revenue stability in the future."

Hanlim Rodex focuses on premium products that enhance design and environmental sustainability, not just simple pedestrian blocks. It maintains a 30% market share in the procurement market by differentiating itself with various colors, shapes, and layering technologies. It offers high-priced products with functionalities such as permeability, impermeability, freeze-thaw resistance, and slip resistance, capturing both image and quality. The company possesses unique know-how in technologies that implement three colors in layers and the mixing ratios of eco-friendly materials.

CEO Kim stated, "In the short term, our goal is to become the number one in the pedestrian block market, and in the long term, to create a company that everyone wants to work for," adding, "We plan to further enhance the sophistication of MES and the level of production automation within this year."

[Gongju, Park So-ra, Reporter]