Smart Factory: Digital maintenance of TRUMPF laser in the global Mercedes-Benz production network

Ditzingen/Stuttgart, 10 June 2024 – 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

Predictive digital maintenance thanks to standardised data infrastructure

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
the Board of Management of Mercedes-Benz Group AG. Production, Quality &
Supply Chain Management.

Condition Monitoring: Monitoring of production systems in real time

In the digital service condition monitoring developed by TRUMPF, the status of
the lasers are now continuously monitored and analyzed 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 recognize 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 and Member
of the Board of Management of TRUMPF

Mercedes-Benz guarantees data protection

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.

About TRUMPF

TRUMPF is a high-tech company offering manufacturing solutions in the fields of machine
tools and laser technology. The Company drives digital connectivity in the manufacturing
through consulting, platform products and software. TRUMPF is one of the technology
and market leader in highly versatile machine tools for sheet metal processing and in the
field of industrial lasers.

In 2022/23, the company employed some 18,400 people and generated sales of about
5.4 billion euros. With over 80 companies, the TRUMPF Group is represented in nearly
every European country as well as in North America, South America and Asia. The
company has production facilities in Germany, France, the United Kingdom, Italy, Austria,
Switzerland, Poland, the Czech Republic, the United States, Mexico and China.
Find out more about TRUMPF at www.trumpf.com