Suzhou, China – November 2025 – Foxconn Technology Group has deployed the ABB CI858K01 3BSE018135R1 communication module across three of its smart electronics factories in Suzhou, enabling rapid product line reconfiguration and a 35% increase in production flexibility. The modules are critical to Foxconn’s “Industry 4.0” transformation, where the ability to switch between smartphone, tablet, and wearable device production in hours—rather than days—has become a competitive advantage.
The Challenge: Rigid Communication for High-Mix, Low-Volume Production
Foxconn’s Suzhou factories faced unique challenges in their shift to flexible manufacturing:
- Slow Line Reconfiguration: Legacy communication modules required manual reprogramming to switch between production lines, taking 48 hours to reconfigure for a new product. With customer demand for custom devices growing, this rigidity led to missed delivery deadlines.
- Device Compatibility Issues: The factories used a mix of ABB drives, Siemens PLCs, and Omron sensors—each with different communication protocols. This forced Foxconn to use 3+ different modules per line, increasing complexity and failure points.
- Limited Scalability: As production volumes fluctuated, the old modules couldn’t easily add or remove devices (e.g., extra robotic arms or quality control cameras) without system downtime.
“In today’s electronics market, speed and flexibility are everything,” said Wang Wei, Foxconn’s Smart Manufacturing Director. “Our old communication system was holding us back—we needed a module that could keep up with our fast-paced production changes.”
ABB CI858K01: The Modular Backbone for Flexible Factories
Foxconn selected the ABB CI858K01 3BSE018135R1 for its modular design, multi-protocol support, and scalability:
- Rapid Reconfiguration: The module’s pre-configured protocol profiles allow technicians to switch between product lines in 2 hours—down from 48. It stores up to 10 different configuration sets, enabling one-touch line changes for high-mix production .
- Universal Device Connectivity: With native support for EtherNet/IP, PROFIBUS DP, and Modbus TCP, the CI858K01 connects ABB drives, Siemens PLCs, and Omron sensors into a single unified network. This reduced the number of modules per line from 3 to 1, simplifying maintenance .
- Plug-and-Play Scalability: The module supports hot-swappable device addition, allowing Foxconn to add 16+ sensors or actuators per line without shutdowns. Its compact design (0.3kg without baseplate) saves 40% of cabinet space compared to legacy modules .
- Real-Time Synchronization: The CI858K01’s 10/100 Mbps Ethernet ports ensure sub-10ms data transfer between devices, critical for synchronizing robotic arms and quality control cameras in high-speed assembly lines .
Results: Flexibility, Speed, and Cost Savings
Nine months after deployment, Foxconn’s Suzhou factories report:
- Production Flexibility Up 35%: Line reconfiguration time dropped from 48 to 2 hours, enabling the factories to handle 20% more product variants without increasing floor space.
- Unplanned Downtime Cut by 50%: Fewer modules and simplified wiring reduced failure points, leading to 8 fewer downtime events in 2025—saving $400,000 in lost production.
- Labor Costs Reduced by 18%: Automated data exchange eliminated 20 manual data entry roles, and faster reconfiguration reduced setup labor by 300 hours monthly.
- Scalability Improved: The factories added 3 new product lines in 2025 without expanding their control systems, thanks to the CI858K01’s ability to support 64+ devices per module .
“The CI858K01 has transformed how we respond to customer demand,” Wang said. “We can now launch a new product line in days, not weeks, which gives us a huge edge in the electronics industry. It’s the unsung hero of our smart factory.”
Kevin Zhang, ABB’s China Industrial Automation Sales Director, noted the module’s alignment with China’s “Made in China 2025” initiative. “Flexible manufacturing is key to competitiveness, and the CI858K01 enables that by breaking down communication barriers,” he said. “Its ability to integrate diverse systems makes it ideal for factories undergoing digital transformation.”
Foxconn plans to deploy the CI858K01 across 12 more factories in Guangzhou and Chengdu by 2026, aiming to reduce overall production lead times by 40%.
