Digital solutions for the manufacturing industry: Boosting efficiency and ensuring quality

Whether harmonizing the IT landscape, implementing automated material flow systems or optimizing overall equipment effectiveness (OEE) – our targeted solutions improve processes holistically, boost efficiency, and sustainably enhance your production performance.

• Harmonization of the IT landscape: Heterogeneous and historically grown IT landscapes make it hard to exchange data and establish data-driven processes. This prevents production workflow optimization and efficiency improvements. As an engineering partner for tailor-made industrial solutions, we assist in harmonizing your IT landscape.
• Increase overall equipment effectiveness (OEE): Through precise data analyses and continuous process monitoring, we unlock potential efficiencies while significantly reducing downtime and rejects. Our portfolio comprises process automation measures and the deployment of advanced technologies that secure stable production flows. This lets us enhance the availability, performance, and quality of systems, leading to improved OEE.
• Automated material flow systems let us achieve vast improvements in production efficiency while simultaneously minimizing manual errors. By integrating innovative software solutions, we create a seamless and optimized flow of materials, which in turn increases both the flexibility and speed in your production environment.

Minimize unplanned downtime and reduce maintenance costs through proactive maintenance strategies based on real-time data.

• With Condition Monitoring solutions, we empower companies to continuously capture and monitor the condition of their machines, enabling early detection of potential issues.
• We use predictive maintenance solutions to help plan maintenance measures in a targeted, proactive manner to maximize operational efficiency and minimize unexpected downtimes. This data-driven strategy not only lengthens the service life of your equipment but can also help optimize maintenance costs.

Industry 4.0 is transforming production through the use of state-of-the-art technologies such as smart automation, the Internet of Things (IoT) and artificial intelligence (AI). We guide you in integrating high-tech system and software solutions to fully leverage the benefits of these technologies.

• End-to-end development partner for smart factory solutions: We support you in the holistic development of cyber-physical and software solutions for the factory of the future. Our development services cover the full range of applications for embedded systems, cloud solutions, mechatronic systems and software applications. In addition, we employ a variety of systems engineering methods – from architecture, requirements engineering and DevOps to cyber security and verification & validation.
• Development support for connected machines and IoT products: With our expertise in embedded systems, cloud integration, and cyber security, we create connected and intelligent machines and production systems that enable real-time communication and data transmission. This provides our clients with the opportunity to develop new business models and secure their competitiveness.

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Whether it’s the seamless integration of IT and OT, the development of scalable data platforms, or the use of artificial intelligence, we embrace a holistic approach that starts with a data and AI strategy and extends to operational execution on the shop floor. We consider technology, organization and compliance together right from the start.

• Scalable data platforms and IT/OT integration: We design and implement industrial data platforms that merge information from MES-driven, ERP-driven and SPS-driven machines and IoT systems in a secure, structured manner. Cloud-based and container-based platform architectures, open interfaces, and DevOps principles let us lay the foundation for end-to-end data flows – enabling data-driven processes in manufacturing and logistics.
• AI deployment: We help you identify and implement AI use cases in manufacturing – such as predictive quality, anomaly detection and automated production data analysis. Our solutions employ machine learning, statistical methods and state-of-the-art approaches like GenAI and foundation models – all seamlessly embedded within existing IT/OT landscapes and operational processes.
• Shop floor digitalization: We guide you through the digital transformation of your entire shop floor – from condition and indicator visualization to operational deviation management. We develop dashboards and Andon boards for the real-time visualization of production data. This approach helps us facilitate effective KPI management as well as structured task and escalation management.
• Data strategy and governance: We advise clients on how to develop and implement sustainable data strategies for manufacturing and logistics – including governance structures, role models and technical guidelines. For this, we also factor in regulatory requirements such as the Data Act, the AI Act and the Digital Product Passport within the framework of the Ecodesign Regulation (ESPR) – with the aim of making data reliable, traceable and future-proof.

Connecting machines and equipment is critical for Industry 4.0 use cases. This involves not only leveraging existing machine data but also generating new data through additional sensor technology. Our “ITK Transparency Toolkit”, for example, is one very cost-effective and extremely easy-to-use tool that enables us to capture, visualize and evaluate machine and process data on demand. We support you in connecting legacy machines and provide expert guidance on selecting the right technologies for new acquisitions. Always with an eye to cost effectiveness.

We map out the entire value chain as a digital twin, reveal bottlenecks, point out system breaks and help optimize processes with precision. Based on the simulation results, we work together with our customers to come up with solutions that boost productivity.

We develop test bench solutions, implement traceability systems, and set up automated testing procedures for your system landscape. As an engineering partner, we are at your side every step of the way – from the very first analysis to concept development and implementation, all the way to smooth operation. We look at the entire process rather than focusing on individual test cases and inspection tasks. Quality assurance, industry-specific standards, and legal requirements are always taken into account.

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• Smart factory consulting: The digitalization of manufacturing calls for a clear strategy, structured change processes and the right combination of technology, organization and people. We support you along every step of the way – from strategic planning and change management to technical implementation. This includes, among others, developing a holistic strategy and roadmap for the smart factory as well as a maturity level analysis and potential analysis for targeted measures.
• Lean management and increased efficiency: We help you effectively implement Lean principles in digital manufacturing – as part of a holistic transformation strategy. To do so, we combine conventional Lean methods such as value-stream mapping, just-in-time approaches and flow principles with digital technologies such as IoT, edge analytics and automated data collection. That lets you create the conditions necessary to reduce waste, shorten throughput times and increase adaptability.
• Technology consulting for digitalization in manufacturing: Choosing the right technologies is pivotal to the success of digital initiatives. With our industry knowledge and technological know-how, we help you select the most suitable technology. We assess current systems, identify potential for improvement, select and integrate new technologies into existing processes.

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Agile methods are a great help in complex development projects – enabling rapid results and making partial successes visible. We draw on our methodological expertise and experience to support you throughout this process.

• Agile transformation: Together, we develop a tailored agile framework for your project – considering your organizational structure, company culture, processes, and technologies.
• Agile services: We have experts on hand in key roles – including Scrum masters and Agile coaches – who are proficient in scaled agile frameworks such as SAFe, Nexus and LeSS.
• Agile coaching: We promote agile working through customized coaching sessions, workshops and on-the-job trainings for team and members of management.

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