One Cab Every 87 Seconds: Inside Dongfeng CV’s D600 Smart Factory

The D600 Smart Factory operated by Dongfeng Commercial Vehicle is currently the world’s largest single-site smart manufacturing facility dedicated to medium- and heavy-duty commercial vehicles.

At this facility, one truck cab-in-white rolls off the production line every 87 seconds on average — a figure that highlights both scale and efficiency.

Automation at the Core

Inside the body assembly workshop, automation defines the production environment.

An overhead EMS conveyor system transports semi-finished cabs steadily across the facility, while Automated Guided Vehicles (AGVs) move along preset routes on the ground to deliver materials with precision.

Despite the fast production rhythm, the workshop remains notably quiet. The absence of excessive noise reflects a highly coordinated and digitally controlled operation. With most processes automated, manual intervention has been significantly reduced, resulting in faster response times and improved overall efficiency.

Fully Automated Welding Operations

The welding workshop features hundreds of robotic arms operating simultaneously. Each robot performs stretching, rotating, gripping and welding tasks under centralized system control.

The automation rate for welding spots has reached 100%.

By replacing repetitive and high-risk manual work, the system not only improves workplace safety but also ensures that every welding point maintains consistent position and strength. This uniformity forms the foundation of stable product quality.

Real-Time Quality Control

Automation is supported by a comprehensive quality monitoring system deployed across the entire production line.

Hundreds of high-precision visual inspection cameras operate around the clock, continuously monitoring components in real time. If an abnormality is detected, the system immediately triggers audio and visual alarms and automatically locks the relevant workstation. Potential quality issues can therefore be intercepted within seconds.

At critical production stages, each cab-in-white undergoes both online body accuracy inspection and offline blue light scanning inspection. All testing data is transmitted in real time to a central analysis platform.

The platform evaluates compliance at the individual unit level and uses data analytics to identify potential risks in advance. This approach makes quality management transparent, traceable and highly precise.

Intelligent and Unmanned Logistics

Logistics plays a central role in maintaining production efficiency at the D600 facility.

An integrated three-dimensional transport network combines overhead APC (Automatic Pallet Carrier) systems and friction lines. On the ground, AGVs ensure point-to-point material delivery with precise timing.

From warehouse storage to final workstation supply, the entire logistics chain operates without manual handling.

As a result, the role of workers has shifted from physical material transport to equipment management, system maintenance, exception handling and process optimization.

Integrating Smart Manufacturing with Green Energy

The D600 Smart Factory also incorporates intelligent energy management solutions.

Large-scale photovoltaic panels installed on the factory roof generate renewable electricity to power production operations. This reduces operating costs while lowering overall energy consumption.

Through this approach, the facility functions not only as a smart factory but also as a green manufacturing site.

Data-Driven Layout Optimization

During the planning phase, simulation software was used to optimize process layout and workflow design.

By analyzing extensive logistics data, engineers calculated the shortest possible paths from parts supply to final assembly. Unnecessary transportation steps and waiting times were eliminated, leading to measurable efficiency gains.

Setting a Benchmark for Intelligent Manufacturing

With digital technologies embedded throughout its operations, the D600 Smart Factory represents more than a high-output production base.

It demonstrates a data-driven manufacturing system capable of responding rapidly to operational changes and market demands.

Through this model, Dongfeng Commercial Vehicle is presenting a practical example of intelligent manufacturing transformation and providing a clear pathway for industrial upgrading in the commercial vehicle sector.

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