Case study: "Introduction of ESB for optimizing engine production processes at Daimler AG / Mercedes-AMG GmbH"

IT support of heterogeneous manufacturing processes in engine production at Mercedes-AMG GmbH

AMG (PresseBox) ( Stuttgart, )
Ranking among the suppliers of motor vehicles most steeped in tradition, Daimler AG manufactures high-performance premium cars through its subsidiary. For best possible IT support of new generation engine production, advanced "Industry 4.0" methods find application to optimize processes while still ensuring high quality.

For adoption of the "Enterprise Service Bus" (ESB) at the Affalterbach production site, Fichtner IT Consulting, in collaboration with the client, designed the communication architecture, assisted in defining the communication formats, installed and configured the ESB, and programmed new system connectors for special-purpose tools. For this project, the IT communication infrastructure of the entire engine manufacturing process was realized by means of a service-oriented architecture to so facilitate optimal interplay of all IT systems, sensors and production equipment. The solution concept is based in particular on state-of-the-art web architecture to monitor, document and orchestrate the technically complex processes.

Thus in productive operation, ESB means that tools can be automatically set up, test and assembly setups individually configured, and all processes monitored and documented. This minimizes setup times, actively supports fitters who work according to the "One Man - One Engine" principle, and eliminates incorrect settings. The ESB sourced from BOSCH SI guarantees reliable communication in engine production between all systems, such as sensors and tools, and in particular ensures complete traceability of reports and signals with loss-free transport of all production equipment. In the production system, several disparate database management and software systems are appropriately linked with each other by means of advanced services installations so as to provide high-performance and reliable support for technical processes.

For the system roll-out project, FIT rendered consulting and implementation services for rapid and secure bi-directional communication and monitoring of sensors, tools, tool and handling equipment positions, and robots as well as of production control and order picking systems in order to further safeguard and optimize the high-end standards of manufacturing processes in AMG engine production. Smart application of innovative IT capabilities for mass data processing thus enables seamless integration of the increasingly available status and sensor information to so obtain precise situation analyses and reliable forecasts in real time.

"High performance and reliability, maximum flexibility, rapid implementation!" 
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