Eaglerise Thailand: Building a Digital Smart Manufacturing Base for Transformers

A Manufacturing Base for Global Markets

As demand continues to grow across renewable energy and data center applications, transformer manufacturers are placing greater emphasis on global manufacturing, localized delivery, and faster response to customers.

Eaglerise Thailand

Eaglerise has established a digital smart manufacturing base in Thailand for medium-voltage oil-immersed transformers, strengthening its global manufacturing and customer service capabilities for markets including renewable energy and data centers. With a planned annual production capacity of 6,000 transformers, the facility serves as an important node in Eaglerise’s global manufacturing network.

For a new manufacturing facility, building production capacity is only part of the challenge. Efficient logistics, production processes, and operational systems are equally important to ensure smooth coordination across manufacturing stages and provide a stable foundation for scalable production.

For Eaglerise’s Thailand facility, AIMStek developed an integrated solution centered on intelligent intralogistics, production line integration, and industrial digitalization, creating an automated production and logistics system covering the major stages of transformer manufacturing.

Integrated Production and Logistics Across Key Manufacturing Processes

Transformers are large and heavy products manufactured through multiple process stages. From core assembly and body assembly to drying, lower-tank assembly, oil filling, settling, and testing, transformer bodies and pallets need to move continuously between different production areas.

To address these requirements, the project integrates heavy-duty material handling equipment, production workstations, and supporting systems into a unified production and logistics system. Automated intralogistics connects different process areas, enabling the automated movement of transformer bodies and pallets across key manufacturing stages.

The system covers the major process flow:

Core & Body Assembly → Pre- and Post-Drying Buffering → Lower-Tank Assembly → Oil Filling → Settling → Testing

This creates an automated production and logistics flow spanning the major manufacturing stages.

Heavy-Duty Intelligent Intralogistics

To handle large transformer bodies and heavy-duty pallets, the project deploys heavy-duty transfer vehicles and multiple RGVs to create an intelligent logistics network across production lines, buffer areas, and downstream process zones.

Heavy-duty RGV

The heavy-duty transfer vehicles handle cross-area transportation of large transformer bodies and pallets, while different types of RGVs are coordinated according to production areas and logistics tasks, enabling automated material flow between production lines.

By coordinating logistics equipment with production takt, the system reduces manual handling and waiting time between processes, providing stable logistics support for continuous heavy-product manufacturing.

Automated Production Line Integration

The project integrates more than 100 workstations with over 100 lifting tables, together with rotary tables, conveyor systems, pallet handling equipment, and other supporting systems.

workstations

At key stages such as body assembly, lower-tank assembly, and body positioning, production workstations and supporting equipment work together to enable automated transfer between processes.

By integrating production equipment with the logistics system, products can move continuously according to predefined process flows, reducing manual intervention while improving production continuity and consistency.

Digital Coordination of Production and Logistics

Building on the automated equipment layer, the project uses the AIMS-MOS Industrial Internet Platform to connect production and logistics operations and provide real-time visibility into equipment and production logistics status.

Production, logistics, and material-related data are consolidated to provide visibility into key manufacturing processes. A material traceability system also records key process information throughout the product journey, supporting production management, quality traceability, and operational decision-making.

This creates a digital chain spanning production tasks, logistics execution, workstation operations, product movement, and process traceability—making the manufacturing floor more transparent, controllable, and traceable.

Improved Manufacturing Efficiency and Capacity

Through the integration of production, logistics, and digital systems, the Thailand facility has achieved improvements across production efficiency, cycle time, inventory turnover, and capacity:

30% Increase in Production Efficiency

Automated heavy-duty logistics, integrated workstations, and coordinated production logistics reduce repetitive manual handling and waiting between processes.

20% Reduction in Production Cycle Time

Automated logistics and coordinated production processes improve the efficiency of handoffs between manufacturing stages.

30% Increase in Inventory Turnover

Greater visibility and coordination across production and logistics processes improve material flow and inventory utilization.

20% Increase in Production Capacity

The coordinated operation of automated production lines and intelligent intralogistics provides stable support for scalable manufacturing.

Building Scalable Smart Manufacturing Capabilities

The Thailand facility is more than a production site. It is an important node in Eaglerise’s global manufacturing and customer service network.

By integrating production, intralogistics, and digital systems, the facility has established an automated manufacturing and logistics system covering its major production processes—providing a stronger foundation for scalable production and responsive delivery to global markets.

From production automation to logistics coordination, and from equipment intelligence to digital manufacturing processes, digital technologies are becoming an essential foundation for the continuous evolution of global manufacturing.

AIMStek combines intelligent intralogistics, production line integration, and industrial digitalization to help manufacturers build smarter, more efficient, stable, and scalable manufacturing capabilities.