Digitalization with a major impact
Success Story
How Webasto is building the foundation for predictive maintenance and sustainable production with connACT
Introduction
Industrial manufacturing is facing new challenges due to shorter product life cycles, growing product and process complexity, and increasing pressure to improve resource efficiency.
To remain competitive, intelligent production solutions are needed. Crucial elements include digitally connected systems, reliable databases, and the ability to immediately react to deviations and exploit potential.
This is where connACT SERVICES, a SITEC service ecosystem, comes in. It offers a modular range that combines traditional industrial services and digital solutions. A central element is connACT ADVANCED, a digital Overall Equipment Effectiveness (OEE) tool that makes machine and process data visible in real time, creating the basis for well-founded decisions.
This collaboration shows how Webasto achieves measurable added value with this solution.
Digital retrofit on Webasto's shop floor
Webasto is a global system supplier to the automotive industry. Headquartered in Stockdorf, Bavaria, Webasto specializes in roof systems, battery-powered electrification, and thermal management solutions.
At its Neubrandenburg site in Mecklenburg-Western Pomerania, Webasto manufactures electric and fossil fuel-powered parking heaters for original equipment and the aftermarket. These products are primarily used in passenger cars and commercial vehicles.
In 2022, the first production system developed by SITEC at the Neubrandenburg plant was equipped with connACT. The integration was completed within a short amount of time. Immediately after commissioning, the first measurable optimization potential was uncovered: Fewer downtimes, lower reject rates and increased process stability.
"In the past, we faced the challenge of precisely specifying errors that occurred on the systems during the shift, especially on the shop floor. The connACT system makes these errors visible, so we can react promptly and effectively." – Sven Kretzschmar, Manufacturing & Engineering, Webasto
Thanks to successful cooperation and customer satisfaction, connACT was extended to all SITEC systems. Today, this digital solution is an integral part of Webasto's continuous process optimization.
Systematically improving energy efficiency
Another key component of connACT is integrated energy monitoring. Consumption of resources such as electricity and compressed air is recorded, analyzed, and visualized in real time.
At Webasto, the system provides transparency about current energy consumption and enables the identification of potential savings during operation. Based on the collected data, measures to reduce energy consumption were defined and successfully implemented.
The benefits are clear: lower operating costs, optimized resource usage, and a step closer to sustainable production.
Condition monitoring and predictive maintenance
With connACT, central machine and system parameters can also be continuously monitored.
Webasto uses condition monitoring to evaluate the condition of its production systems in real time. By identifying process anomalies early on, maintenance measures can be planned more effectively. This has significantly reduced the NOK rate.
This predictive maintenance strategy increases the technical availability of machines while reducing maintenance costs. In this way, connACT establishes the foundation for greater process reliability and minimizes the risk of costly production downtime.
Added value through data intelligence
The project with Webasto in Neubrandenburg demonstrates how connACT contributes to the data-driven optimization of manufacturing processes. This innovative solution helps manufacturing companies improve system performance, reduce operating costs, and create more sustainable processes.
"In the future, we want to use connACT for all systems from other manufacturers at our plant. We want to display a uniform level of information for all systems on the shop floor to further increase production efficiency," Kretzschmar emphasizes.
Since 2020, all new SITEC systems have come equipped with the OEE tool. However, existing systems from other manufacturers can also be easily retrofitted.
Contact
Would you like to learn how connACT can help you develop your production more efficiently and sustainably?
Schedule a free consultation, and we will demonstrate your data's potential.
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Über SITEC
SITEC ist ein international geschätzter Partner und Systemlieferant für automatisierte High-tech-Produktionsanlagen sowie der Serienfertigung von Präzisionsteilen und Baugruppen.
Basierend auf höchsten Qualitäts- und Umweltstandards bietet SITEC effiziente Fertigungstechnologien sowie schlüsselfertige Komplettlösungen.
Für seine weltweiten Kunden der Automobilindustrie, Medizintechnik und alternativenEnergietechnik entwickelt SITEC serienreife Lösungen zur automatisierten Montage, Lasermaterialbearbeitung und elektrochemischen Metallbearbeitung. Das gelingt dem Unternehmen mit rund 300 hoch qualifizierten Mitarbeitenden und einem optimalen Teamwork.
SITEC wächst dabei mit den Herausforderungen seiner Kunden und des Marktes, wie beispielsweise der Entwicklung neuer Produkte im Bereich der E-Mobilität oder autarker Speichertechnologien auf Basis von Brennstoffzellen. Vollautomatisierte Laserbearbeitungsanlagen zum Laserschweißen, insbesondere von Kupfer für Bauteile im E-Antrieb, Batteriesystemen und der Leistungselektronik, gehören heute zum Portfolio.
Darüber hinaus produziert das Unternehmen seit 2012 innerhalb der Serienfertigung lasergeschweißte Bipolarplatten verschiedener Designs im Kundenauftrag.
Das 1991 gegründete Unternehmen mit Hauptsitz in Deutschland bedient asiatische Märkte direkt vor Ort über die SITEC Laser Technology (Shanghai) und betreibt in den USA (Pittsburgh) einen Showroom
Kontakt
SITEC Industrietechnologie GmbH
Bornaer Straße 192
09114 Chemnitz
Deutschland
Ansprechpartner
Sabine Rabenhold
Mediensprecherin
Telefon: +49 371 4708 273
sabine.rabenhold@sitec-technology.de