The advancement of technologies such as artificial intelligence (AI), 5G networks, and the industrial internet has sparked an ongoing transformation in global manufacturing, where smart manufacturing and digitalization are rapidly gaining momentumThe concept of "lighthouse factories" has emerged as a guiding principle in this shift, representing the pinnacle of smart manufacturing and digitalization practices under the umbrella of Industry 4.0. These factories are distinguished by their innovative approaches to production, showcasing the best use of technology to enhance efficiency and sustainability.

Recently, the World Economic Forum announced the inclusion of 17 new members to its prestigious list of lighthouse factories, with the Citic Dicastal Morocco plant standing out as a significant additionThis factory, affiliated with the Citic Group, proudly claims the title of Africa's first lighthouse factory

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Its selection serves as evidence of the fruitful collaboration between China and Morocco in building the "Belt and Road" initiative, marking a major step forward in economic development and industrialization within Africa.

Located in the Atlantic Free Trade Zone of Kenitra, Morocco, the Citic Dicastal facility covers an impressive area of about 25.33 hectares, housing three phases of production including aluminum wheels and aluminum castingsWith a capacity to produce six million aluminum wheels and five million aluminum castings annually, it stands as the largest investment project following the establishment of a strategic partnership between China and MoroccoThis undertaking is particularly noteworthy given Africa's relatively weak industrial infrastructure and limited technical expertiseThe quick transition from project initiation to its eventual recognition as a lighthouse factory—achieved in a mere eight months—highlights the efficacy and robustness of the solutions pioneered under the "China Standard" for transforming traditional manufacturing.

Within the Citic Dicastal Morocco plant, AI technology and big data analytics are intricately woven into every stage of production

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The factory exemplifies the full utilization of intelligence and digitization, where autonomous analysis, decision-making, adaptation, and self-learning have become routineThis continuous flow of operations ensures that production remains efficient, stable, and smartFrom the selection of raw materials to the packaging of finished products, every step is managed through precise control by intelligent systems that optimize performance in real-time, thereby laying the groundwork for innovative smart manufacturing possibilities in Africa.

The World Economic Forum has lauded the Citic Dicastal plant for its proactive approach to industry challenges and its commitment to the lightweighting trend that is reshaping the automotive sectorThe factory has implemented over 40 digital use cases, applying advanced algorithms to casting and processing operationsIt has also installed an AI-enhanced visual inspection system and adopted process control methods to address fluctuations in natural gas quality within melting furnaces

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Thanks to these initiatives, the factory experienced a 17% boost in overall equipment effectiveness, a 27% rise in labor productivity, and a significant 31.1% reduction in product defect ratesPresident Bad Rahmoudi emphasized that the lighthouse factory initiative has evolved the company's digital and AI solutions, profoundly impacting supply chains in Morocco and the wider African continent.

In addition to its cutting-edge technology, the factory is dedicated to environmental sustainabilityCitic Dicastal Morocco demonstrates a deep understanding of and respect for the unique conditions of the African region, meticulously integrating energy conservation and emissions reduction into every facet of its production processesBy utilizing big data for real-time consumption tracking, optimizing control through AI algorithms, and implementing software upgrades, the plant has effectively minimized resource waste while enhancing energy efficiency

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Notably, direct emissions (Scope 1) from its buildings and vehicles, as well as indirect emissions (Scope 2) from purchased energy, have decreased by 53%. This accomplishment addresses practical challenges such as the low recycling rate of aluminum resources and significant fluctuations in natural gas heating values within the African context, substantially elevating the concept of “green productivity.”

The Citic Dicastal Morocco facility is also recognized as the first factory in Africa to receive the PAS 2060 carbon neutrality certification from Bureau VeritasBuilding on its success, the plant collaborated with the Moroccan Institute for Standardization to develop national standards for green supply chains and the establishment of zero-carbon factories, further aiding Morocco’s industrial green transitionIts exemplary performance in promoting sustainable development earned the factory the Moroccan National Industrial “Decarbonization Award” in July 2024.

In line with the proverb that teaches one to fish, rather than simply providing fish, the Citic Dicastal Morocco factory creates over 1,800 job opportunities for the local community while empowering Moroccan employees to realize their full human potential through innovative management practices

The plant frequently organizes training programs and cross-border exchanges for Moroccan staff in China, and has initiated a “Chinese Workshop” at the factory, fostering the sharing of global best practices in manufacturing and managementThis endeavor significantly contributes to the training of skilled labor and globally minded talent within the local workforceNotably, among the first batch of Moroccan employees trained in China, more than 60 have advanced to become core team members, with over 10 taking on managerial roles.

President Bad Rahmoudi also highlighted that Citic Dicastal Morocco is pioneering aluminum wheel and component casting in Morocco, further underlining its commitment to cooperation with local universities for the recruitment of engineers and collaboration with local suppliersThese efforts collectively contribute to the growth of the aluminum casting industry's ecosystem in Morocco and across Africa.