Mercedes-Benz and high-tech company TRUMPF have strengthened their long-standing partnership to enhance the resilience and efficiency of complex production systems through predictive digital maintenance in the age of the Smart Factory. This collaboration focuses on the real-time maintenance of TRUMPF lasers, essential components in Mercedes-Benz’s global production network.
The innovative approach, piloted at the Sindelfingen site, has now been extended to all Mercedes-Benz plants worldwide. This transition to digital maintenance is expected to significantly reduce the risk of unplanned machine downtime, thereby improving the overall resilience of vehicle production processes.
Predictive Digital Maintenance Through Standardized Data Infrastructure
Traditionally, laser maintenance was performed at fixed intervals, with data management and documentation handled manually. With the adoption of Manufacturing Service Bus (MSB) and the global MO360 data infrastructure, approximately half of the 400 TRUMPF lasers and associated optics used worldwide by Mercedes-Benz are now connected in a cloud-based system.
Jörg Burzer, Member of the Board of Management of Mercedes-Benz Group AG, Production, Quality & Supply Chain Management, stated, “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 optimization with innovative condition monitoring even in system maintenance.”
Condition Monitoring: Real-Time System Surveillance
The condition monitoring system developed by TRUMPF allows for continuous, real-time monitoring and analysis of laser status via the cloud. Service experts utilize algorithms to centrally monitor the networked lasers, detecting and reporting abnormalities immediately to the relevant maintenance departments, along with recommended actions. This proactive approach enables Mercedes-Benz to address additional maintenance requirements before a laser fails, thereby preventing unplanned downtimes and significantly reducing breakdowns. Over 80% of service cases can now be predicted and proactively managed.
Hagen Zimer, CEO Laser Technology and Member of the Board of Management of TRUMPF, emphasized, “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.”
Data Protection and Global IT Standardization
Mercedes-Benz ensures data protection through a globally uniform IT architecture and standardized components across all assembly and vehicle plants. Only laser status data is sent to the TRUMPF cloud for analysis, protected by rigorous cloud assessments and audits, ensuring no production-relevant data is shared with third parties.
TRUMPF is a high-tech company offering manufacturing solutions in machine tools and laser technology. The company is a leader in digital connectivity in manufacturing through its consulting, platform products, and software. In the 2022/23 fiscal year, TRUMPF employed around 18,400 people and generated sales of approximately 5.4 billion euros. The TRUMPF Group operates in almost every European country and has production facilities in Germany, France, the UK, Italy, Austria, Switzerland, Poland, the Czech Republic, the US, Mexico, and China.
This collaboration between Mercedes-Benz and TRUMPF marks a significant advancement in the use of digital technologies to enhance production efficiency and reliability, setting a new standard in the automotive manufacturing industry.
