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    Feb 11, 2025

    Behind the scenes of our new manufacturing hub for Entertainment in China

    2024 stories · Corporate · Innovation · Entertainment · 3 min read

    In May 2024, Barco unveiled its state-of-the-art 15,000m2 R&D and production plant in Wuxi, China. Focusing on the projector market, the new site fully embodies Barco’s strategy to boost efficiency through focused factories. More than that, it testifies to Barco’s resolute belief in a strong, local presence in China. We sat down with Gao Yang, VP Operations Wuxi, to reflect on the past challenging, yet rewarding, months.  

    Why did Barco choose to relocate the projection plant from Beijing to Wuxi?

    Gao: "There are several reasons. First of all, the Wuxi authorities actively promote the region to manufacturing, engineering and technology firms through subsidies and financial support. More than that, Wuxi’s strategic location near Shanghai is a stimulus for international companies, including many of our customers, to settle there. For Barco, this means seamless supply chain integration. Lastly, the region offers a skilled talent pool at relatively lower costs, making it an ideal choice for our operations."

    Why did Barco choose to relocate the projection plant from Beijing to Wuxi?

    Gao: "There are several reasons. First of all, the Wuxi authorities actively promote the region to manufacturing, engineering and technology firms through subsidies and financial support. More than that, Wuxi’s strategic location near Shanghai is a stimulus for international companies, including many of our customers, to settle there. For Barco, this means seamless supply chain integration. Lastly, the region offers a skilled talent pool at relatively lower costs, making it an ideal choice for our operations."

    Moving an R&D and production facility seems daunting. How did it go?

    Gao: "We pulled it off in time, so I’m very happy about everyone’s hard work and dedication. After all, closing a site after two decades of operations isn’t something you do overnight. It required extensive preparation and coordination to ensure a smooth transition.

    Beyond moving equipment and raw materials, 30% of our white-collar workforce moved with us until the end of 2024. The others had to find new jobs, so the closure of the Beijing plant had a significant impact on our workforce. Barco is a truly people-oriented company, so supporting our staff through these changes was a top priority. We devoted a lot of time to communications with people."

    How has automation been integrated into the new facility, and what benefits do you see so far?

    Gao: “Currently, the Wuxi factory has achieved 50% automation. The warehouse is fully automated, with material-picking systems and robotic transportation in place. Automated Guided Vehicles and Automated Machine Robots help us move goods efficiently. We’re already seeing the first benefits: the technology has enabled the factory to meet and even exceed the production capacity of the original Beijing site.

    Looking ahead, we plan to intensify our efforts, with the goal of fully automating the production lines by 2027. AI, robots, and sensing technologies will play a key role in improving efficiency in assembly, testing, and packaging. That said, it’s important to note that we will still need skilled talent to manage processes, think critically, and provide support.”

    How has automation been integrated into the new facility, and what benefits do you see so far?

    Gao: “Currently, the Wuxi factory has achieved 50% automation. The warehouse is fully automated, with material-picking systems and robotic transportation in place. Automated Guided Vehicles and Automated Machine Robots help us move goods efficiently. We’re already seeing the first benefits: the technology has enabled the factory to meet and even exceed the production capacity of the original Beijing site.

    Looking ahead, we plan to intensify our efforts, with the goal of fully automating the production lines by 2027. AI, robots, and sensing technologies will play a key role in improving efficiency in assembly, testing, and packaging. That said, it’s important to note that we will still need skilled talent to manage processes, think critically, and provide support.”

    Our goal is to fully automate the production lines by 2027. Of course, we will still need skilled talent to manage processes, think critically, and provide support.

    Gao Yang,

    VP Operations Wuxi, Barco China

    Wuxi focuses on projector technology. What products are you engineering and producing?

    Gao: “We’re manufacturing various projector models, including the compact, laser UDX projector, the UDM series, and the F-70 simulation projector. In addition, the Wuxi factory supplies key components such as light pipelines and holders to other Barco factories. So, we support the overall operations of Barco's global manufacturing network.”

    The new I600 projector is also being produced in Wuxi, isn’t it?

    Gao: That’s right. The I600 projector was jointly developed in Beijing and Wuxi, with 80% of its supply chain based in China, making it a very cost-effective product. It offers a range of lumens from 8,000 to 14,000, delivering impressive picture quality at a competitive price. This makes it an ideal solution for the entry-level market, particularly in corporate AV and simulation applications.

    Wuxi focuses on projector technology. What products are you engineering and producing?

    Gao: “We’re manufacturing various projector models, including the compact, laser UDX projector, the UDM series, and the F-70 simulation projector. In addition, the Wuxi factory supplies key components such as light pipelines and holders to other Barco factories. So, we support the overall operations of Barco's global manufacturing network.”

    The new I600 projector is also being produced in Wuxi, isn’t it?

    Gao: That’s right. The I600 projector was jointly developed in Beijing and Wuxi, with 80% of its supply chain based in China, making it a very cost-effective product. It offers a range of lumens from 8,000 to 14,000, delivering impressive picture quality at a competitive price. This makes it an ideal solution for the entry-level market, particularly in corporate AV and simulation applications.

    Barco sets a great example with its sustainability efforts. Does the Wuxi plant check all the boxes?

    Gao: Barco’s sustainability strategy is implemented across the entire company, regardless of geography, so we have uniform targets everywhere. Moreover, the factory is located in a high-standard environmental zone and adheres to strict government regulations. We’ve implemented solar panels and energy-saving policies to reduce our carbon footprint, for instance. And as I mentioned, Barco is exceptionally people-oriented, including in China. We make a strong effort to engage our staff, provide them with learning opportunities and maintain open communication. Our bi-annual employee satisfaction surveys shows that these efforts are greatly appreciated.

    Looking ahead, what are the key priorities for the Wuxi site in the coming years?

    Gao:  Our immediate focus is stabilizing the team, especially with the 30% of staff who returned to Being by the end of the year. We’re hiring new team members to fill these positions and we’re rebuilding competencies to ensure we continue to move forward. At the same time, we’re working on two exciting new products and continuing our efforts to step up automation and efficiency. These initiatives will help us maintain our competitive edge and meet the growing demands of our market.

    Looking ahead, what are the key priorities for the Wuxi site in the coming years?

    Gao:  Our immediate focus is stabilizing the team, especially with the 30% of staff who returned to Being by the end of the year. We’re hiring new team members to fill these positions and we’re rebuilding competencies to ensure we continue to move forward. At the same time, we’re working on two exciting new products and continuing our efforts to step up automation and efficiency. These initiatives will help us maintain our competitive edge and meet the growing demands of our market.

    Barco’s sustainability strategy is implemented across the entire company, regardless of geography, so we have uniform targets everywhere.

    Gao Yang,

    VP Operations Wuxi, Barco China

    Read Barbara's story about how the I600 came to life.

    About Gao Yang

    • VP Operations Wuxi at Barco China since 2019 
    • Joined Barco in 2010 as GM of LED business
    • Prior to that: active at Philips since 1993

    Gao’s advice

    "United as a blazing fire, apart as twinkling stars."