Our client faced significant challenges in traceability across production, workforce, and maintenance management. They also struggled with process audits, root cause analysis, rework, and energy overuse. The lack of enterprise-wide visibility was also causing increased inefficiencies leading to a surge in operational overheads across their manufacturing cycle.
Intelligent connected sensors
Supervisory Control and Data Acquisition (SCADA)
Bosch DeviceBridge
Custom-made applications on cloud and on-premises
Advanced analytics
Currently, automotive manufacturers stand at a crucial intersection – meeting the needs of increasingly demanding customers and setting new benchmarks to stand out in the competitive market. On one hand customers seek advanced products or features enabling more convenient and safer driving. On the other hand, the industry is prioritizing circular economy, cybersecurity regulations, and advanced digitalization to cater to evolving manufacturing standards. Today, it is mission-critical for all industrial manufacturing companies to deploy cutting-edge industry 4.0 solutions powered by the Industrial Internet of Things (IIoT) that can help them address issues such as design irregularities and gaps in component assembly that can gravely affect vehicle performance, user comfort and safety. Empowering the skilled workforce with the right technology is equally essential for such firms aiming to streamline production operations, energy allocation, and cost optimization, besides driving stringent quality control measures.
Our client, a renowned legacy manufacturer, faced similar challenges and critically needed to enhance traceability, process efficiency, and energy optimization across the production cycle. They sought product and process management systems with modernized capabilities that could empower them with end-to-end visibility. They wanted to integrate advanced smart factory technologies to augment their lean manufacturing strategies, thereby improving product quality, process audits, and workforce effectiveness.
Implementing a customized solution for the client meant having contextual knowledge of their organizational and, most importantly, production landscapes. With Bosch’s pioneering expertise in manufacturing processes across the value chain — a modular approach was proposed — encompassing the client’s data repositories, machines and equipment, and supply chain – seamlessly woven into their strategic imperatives.
To achieve this, we deployed our trusted, smart factory deployment process that operates at operating at 4 distinct levels — Cognition, Consume, Collect, and Connect.
We deployed advanced analytics to analyze and manage material allocation, rework time, handling and disposal, and energy usage and management. Moreover, our native capabilities such as Supervisory Control and Data Acquisition (SCADA) systems, Programmable Logic Controller (PLCs), and Bosch SDS in-house solutions such as Bosch Production Visualizer (BPV), Bosch Quality Assistant (BQA), Smart Manpower Planning (SMP), Maintenance Management (MM), Traceability (TR), Integrated Energy and Utilities Management Platform (IEP), and Bosch DeviceBridge, and helped the client reap the following benefits:
Implemented machine connectivity and data acquisition layer with Bosch DeviceBridge, enabling seamless data collection.
Real-time visibility into production-floor KPIs and downtime data with cloud/on-premise visualization solution BPV.
We enabled the workforce to take corrective action against station rejections and inefficient processes with BQA.
Automated workforce allocation depending on skill and requirement with SMP.
Integrated predictive maintenance with MM, minimizing downtime and extending machinery lifespan.
Enhanced traceability across production lines with TR, ensuring product quality and compliance.
Ensured comprehensive energy analytics and sensor monitoring with Bosch IEP, optimizing energy usage.
Bosch SDS analyzed the client landscape to identify gaps in traceability and product quality processes. We enabled the client to discover that their key to future-centric resilience lies in propelling connectivity, process efficiency, resource allocation, and cost optimization across the production lifecycle. Through 360-degree organizational visibility, the client could now efficiently handle production processes with our modular end-to-end IIoT solution.. The client was also able to accelerate their go-to-market period, and achieve better product outcomes and enhanced value creation at every turn with our consultative approach and tailored modular solutions.
Estimated savings of $2.5 million, realized through the deployment of customized IIoT solutions.
6-10% reduction in scrap rates, significantly lowering material wastage.
10% improvement in conversion costs and workforce redeployment.
Enhanced energy efficiency due to energy analytics and green initiatives.
Reduction in rework due to improved product and process quality
Our custom I4.0 solutions are a result of our decade-long proven expertise and industrial exposure in driving smarter digital solutions for this new era of intelligent businesses. We empowered our client with the right mix of advanced technologies, sustainable processes, and a unified digital engineering approach to boost their traceability and product quality, helping them navigate the manufacturing complexities in a cost and energy-efficient way.
