Mercedes-Benz and the high-tech company Trumpf have been working closely together for decades to make the use of complex systems in production more resilient and efficient. In the field of real-time laser maintenance, both companies are focusing on predictive digital maintenance in the age of the smart factory. The corresponding pilot project at the Sindelfingen plant served as a blueprint for all Mercedes-Benz plants worldwide. The innovative process significantly reduces the risk of unplanned machine downtime, which greatly increases the resilience of the complex vehicle production processes.

Previously, laser maintenance was carried out at fixed intervals directly on the systems at the respective locations. Master data maintenance, documentation and data exchange were carried out manually. With the help of the Manufacturing Service Bus (MSB) and additional elements of the global MO360 data infrastructure, a good half of the approximately four hundred Trumpf lasers and associated laser optics used at Mercedes-Benz worldwide are now connected in a cloud. 

“The future of automotive production lies in predictive, digital processes, dynamic maintenance and maximum failure protection. Together with our partner Trumpf, we are also driving continuous process optimization in plant maintenance with innovative condition monitoring,” says Jörg Burzer, member of the management board of Mercedes-Benz.

In the digital service condition monitoring developed by Trumpf, the condition of the lasers is now monitored and analyzed continuously and in real time using cloud-based technology. Trumpf’s service experts use algorithms to monitor the networked lasers centrally from a single point during machine operation. Anomalies are detected immediately and reported directly to the relevant maintenance department, accompanied by recommendations for action. Mercedes-Benz is therefore able to identify additional maintenance requirements before a laser fails. The risk of failure is therefore predictable and can be prevented by initiating maintenance measures in good time. This avoids unplanned downtime in production and significantly reduces downtime. More than eighty percent of all service cases can be predicted and proactively planned.

In addition, the results of these analyses help Mercedes-Benz to operate the lasers more efficiently and thus assist in the continuous optimization of its high-tech vehicle production.

“Digital networking is the key to greater efficiency in production. We strengthen our customers’ competitiveness with smart factory solutions. Through condition monitoring and data analysis, we support our partner Mercedes-Benz in its state-of-the-art production and increase the availability of our lasers and machines,” says Hagen Zimer, CEO laser technology and member of the Trumpf management board.