Mercedes-Benz and high-tech company TRUMPF honed their decades-long relationship to make complex systems in production more resilient and efficient. In the age of Smart Factory both companies are focusing on predictive digital maintenance the field of real-time laser maintenance. The corresponding pilot project at the Sindelfingen site served as a blueprint for all Mercedes-Benz plants worldwide. The innovative process significantly reduces the risk of unplanned downtime of machines, which enormously increases the resilience of complex vehicle production processes.

Until now, lasers have been serviced at fixed time intervals directly in their respective locations. Master data maintenance, documentation and data exchange were carried out manually. With the help of Manufacturing Service Bus (MSB) and additional elements of the global MO360 data infrastructure, around half of the approximately 400 TRUMPF lasers and associated laser optics used worldwide at Mercedes-Benz are now connected in one cloud.

“The future of automotive production is about forward-looking, digital processes, dynamic maintenance and maximum failure avoidance. Together with our partner TRUMPF, we are driving forward continuous process optimisation with innovative condition monitoring even in system maintenance", said Jörg Burzer, Member of Board of Management, Mercedes-Benz Group AG.

In the digital service condition monitoring developed by TRUMPF, the status of the lasers are now continuously monitored and analysed cloud-based in real time. In so-called condition monitoring, TRUMPF service experts use algorithms to monitor the networked laser centrally from a single point while the machine is in progress. Abnormilities are detected immediately and reported directly to the corresponding maintenance department, accompanied by recommended actions. Mercedes-Benz is therefore able to recognise additional maintenance requirements before a laser fails. The risk of a failure is so predictable and can be prevented by maintenance measures initiated on time. This avoids unplanned downtimes in production and significantly reduces breakdowns. Over 80% of all service cases can be predicted and proactively planned.

In addition, the results of these analyses help Mercedes-Benz to operate the laser better and therefore assist in the continuous optimization of its high-tech vehicle production.  

“Digital networking is the key to greater efficiency in production. With smart factory solutions, we are strengthening the competitiveness of our customers. Through condition monitoring and data analyses, we support our partner Mercedes-Benz in its state-of-the-art production and increase the availability of our laser and machines”, said Hagen Zimer, CEO- Laser Technology & Member of Board of Management, TRUMPF.

Thanks to a globaly uniform IT architecture and standardization of the components in all assembly and vehicle plants worldwide, the highly complex production facilities are validated. Production-relevant data is not passed on to third parties. Only the laser status data is sent to the TRUMPF cloud for analysis, whereby the data streams are protected by cloud assessments and audits.