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Dark factory strategy
We assess industry traits and infrastructure in depth and build the adoption strategy and roadmap.
Dark Factory & Physical AI Partner
From diagnosis to build and operation,
we re-invent the factory floor
With Physical AI and robotics, we remove the limits of the factory floor and build dark factories that judge and act on their own.
Mission
With Physical AI and robotics, we remove the limits of the factory floor
Vision
People focus on higher-value decisions, while the factory runs itself
Values
Field execution · ROI-driven · Sustained operation
Why Dark Factory
Dark factories focus on two goals: lower cost and stable quality
Skilled labor gap
Retiring veterans take shop-floor knowledge with them, and hiring gets harder.
Rising fixed costs
Labor and energy costs keep rising structurally.
Quality variance
Human visual inspection cannot catch micro-defects consistently.
Unplanned downtime
One breakdown halts the whole line and delivery dates with it.
Replacing the limits of partial automation with an autonomous operating system
| Partial automation (AS-IS) | Dark factory (TO-BE) | |
|---|---|---|
| Approach | Automation added machine by machine | Whole process designed as one operating system |
| Operations | People monitor constantly and respond manually | AI judges status and responds automatically |
| Quality | Sampling inspection, defects found after the fact | 100% real-time inspection, anomalies caught early |
| Plant operation | Run on the skill of a few master operators | Data-driven autonomous operation |
| Scalability | Line changes require physical reconfiguration | Lines switch through software updates |
Our Services
Getting dark factories running on your floor, fastest
FactoryLab.Ai delivers the full dark factory transformation, from strategy to day-to-day operation.
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Intelligent system build
From IIoT data pipelines to Physical AI, agentic AI, LLM, digital twin and ontology-based RCA.
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IT-OT ops optimization
We keep improving manufacturing system performance through IT-OT convergence and data.
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Web data & AI data infrastructure (Bright Data)
As a Bright Data partner, we use its web data APIs and datasets to source external market, pricing and supply-chain data and connect it to AI model training, ontologies and agents.
How We Work
Five stages from diagnosis to autonomous operation
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01
Design thinking workshop
Share why the transition is needed and peer cases, and review realistic outcomes together.
Deliverable · Press Release · FAQ
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02
Site diagnosis (2–4 wks)
We deploy on site to assess process and data maturity and gather requirements.
Deliverable · Diagnosis report · ROI simulation
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03
PoC build & validation
We build a pilot with minimum core features and verify whether real KPIs are met.
Deliverable · PoC results report
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04
Incremental upgrades
Roll out validated segments first and adjust direction at each checkpoint.
Deliverable · Commercialization plan
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05
Performance-based operation
After confirming KPI results, we move to ongoing operation and continuous upgrades.
Deliverable · Performance report
Each stage ends with a performance report and Go / No-Go criteria for the next stage.
Industries
Every consultant, including our CEO, has proven references
- Automotive & parts Press, welding, painting, assembly, inspection, logistics, maintenance, quality history
- Secondary batteries Electrode, assembly, formation, inspection, cleanroom, process variation, yield analysis
- Electronics & semiconductors SMT, mounting, visual inspection, metrology, utilization, predictive maintenance, yield
- Refining & chemicals Blending, reaction, purification, packaging, safety monitoring, energy optimization
- Aerospace & defense Systems engineering, V&V · traceability, configuration management, FMEA · DRBFM, SoS
Our Platform · Ontology & Agentic AI
We connect scattered operating data into one ontology, then trace cause and effect
Ontology & BI
Upload OT data (sensors, PLC, SCADA, DCS) and IT data (MES, ERP, SCM); it is recognized and linked as objects and relationships automatically.
Root cause tracing
Find core hubs by centrality and PageRank, and trace N-hop paths and scores from an issue to candidate causes. Ask in plain language and the graph answers.
AI guide agent Onto
Briefs findings by voice and coordinates execution, from owner assignment to approval and audit trails. Supports Korean, English, Japanese and Chinese.
References
Reference 1
Dark factory consulting and platform build PMO for refining & petrochemical process optimization
An ISA-95-based program applying LLM, Physical AI, agentic AI and ontology. We designed role-specific AI experiences, and ontology gives equipment data context so multiple AI agents tune operation. Physical AI manages fleets of same-type equipment via PLC/SCADA with humans in the loop.
ISA-95 · LLM · Agentic AI · Physical AI · Ontology
Reference 2
Designing and appraising processes for security- and safety-critical systems
NASA (US) · Space
Overhauled SE processes — V&V, traceability, baseline and release management
B Aircraft Maker (US)
Aircraft SE processes and a FMEA · DRBFM-based prevention framework
L Defense Co. (Korea)
Integrated SoS SE process and verification framework
LG Electronics Automotive
Automotive SPICE assessment — diagnosis, roadmap and pilot
POSCO
SE processes for the Pohang and Gwangyang sites and company-wide rollout
Large global and Korean manufacturers
PLC/SCADA-linked data lake and control-to-information network boundary architecture
CEO & Founder
Yeunsae (Tony) Jang
CEO & Founder, FactoryLab.Ai
- CEO, FactoryLab.Ai — Manufacturing IT-OT, ISA-95 and Physical AI consulting
- Former Vice President, Head of SDx Division, Hyundai AutoEver
- Former Executive Director, Dark Factory Technology, Hyundai Motor Singapore HMGICS
- Former Head of IT Technology R&D Group, POSCO DX
- Former Professional Services, AWS
- Former Director, Technology Innovation Group, Deloitte
- Former Systems Engineering Consulting, IBM GBS Korea
- Former Professor, Suwon Science College
Credentials
- IBM Certified CMMI / ITIL Internal Appraiser
- IBM Certified System Engineer & T3 Trainer
- IONA Certified Enterprise Architect (Master)
- 2019 Korea ICT Grand Prize (Minister’s Award)
- Author of two books on systems analysis and design (UML)
Partners
Our partners
Sister company · Smart Factory Consulting, SI & PMO
Qualigent
FactoryLab.Ai and Qualigent are sister companies that jointly pursue manufacturing DX/AX/RX and share people and business infrastructure.
Web Data Partner
Global web data platform. We work together to source the public external data that AI models and ontologies need.
Let us find the right first step for your plant
Request a free assessment & consultation- Phone
- +82-2-518-0704
- Address
- Room 1223, Geopyeong Town, 129 Bongeunsa-ro, Gangnam-gu, Seoul, Korea
Get directions on Google Maps →© OpenStreetMap contributors
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