Software AG Case Studies IIoT Analytics Revolutionizing the Automotive Painting Industry: A Case Study on Dürr

Edit This Case Study Record

	IIoT Analytics Revolutionizing the Automotive Painting Industry: A Case Study on Dürr Software AG

IIoT Analytics Revolutionizing the Automotive Painting Industry: A Case Study on Dürr

Software AG

Technology Category	Sensors - Air Pollution Sensors Sensors - Environmental Sensors
Applicable Industries	Automotive Equipment & Machinery
Applicable Functions	Maintenance
Use Cases	Manufacturing System Automation Predictive Maintenance
Services	System Integration
Challenge	Dürr, a leading mechanical and plant engineering firm, faced several challenges in its operations. The company was under pressure to meet customer demand for secure monitoring of production data and self-service predictive maintenance capabilities. There was also a need to avoid painting faults caused by materials or equipment wear. Dürr was also grappling with growing ESG requirements to cut energy use and emissions. The company was in the process of transforming from traditional manufacturing to a digital business, which presented its own set of challenges. Read More
About Customer	Dürr is one of the world’s leading mechanical and plant engineering firms. Its turnkey paint shops, final assembly systems, and machine and robot technology harness digitalization and Industry 4.0 concepts to power manufacturing across the automotive industry. Dürr generates over €3.5 billion in revenue annually, and its paint shops, used by every major automaker globally, have achieved massive energy consumption savings. The company has been a leader in mechanical engineering since Paul Dürr opened his first metal workshop in 1895 in Germany. Read More
Solution	Dürr adopted the Cumulocity IoT Platform to address its challenges. The company implemented real-time monitoring for 64 robots, which accelerated customer growth and planned robot purchases. Dürr also co-developed self-service analytics tools for operational engineers, which helped generate new revenue streams from innovative digital services. The system consists of an industrial PC located next to each robotic paint station which has an IIoT edge installation that can control all painting processes, monitor for defects and alert operators to customized triggers. Using self-service predictive maintenance and anomaly detection, air nozzles are now cleaned only when needed to prevent contamination. Defective paint runs due to contaminated shaping air nozzles no longer happen because the new system detects such faults immediately. Read More Log in to view content
Contents

Technology Category

Sensors - Air Pollution Sensors

Sensors - Environmental Sensors

Applicable Industries

Automotive

Equipment & Machinery

Applicable Functions

Maintenance

Use Cases

Manufacturing System Automation

Predictive Maintenance

Services

System Integration

Challenge

Dürr, a leading mechanical and plant engineering firm, faced several challenges in its operations. The company was under pressure to meet customer demand for secure monitoring of production data and self-service predictive maintenance capabilities. There was also a need to avoid painting faults caused by materials or equipment wear. Dürr was also grappling with growing ESG requirements to cut energy use and emissions. The company was in the process of transforming from traditional manufacturing to a digital business, which presented its own set of challenges.

About Customer

Dürr is one of the world’s leading mechanical and plant engineering firms. Its turnkey paint shops, final assembly systems, and machine and robot technology harness digitalization and Industry 4.0 concepts to power manufacturing across the automotive industry. Dürr generates over €3.5 billion in revenue annually, and its paint shops, used by every major automaker globally, have achieved massive energy consumption savings. The company has been a leader in mechanical engineering since Paul Dürr opened his first metal workshop in 1895 in Germany.

Solution

Dürr adopted the Cumulocity IoT Platform to address its challenges. The company implemented real-time monitoring for 64 robots, which accelerated customer growth and planned robot purchases. Dürr also co-developed self-service analytics tools for operational engineers, which helped generate new revenue streams from innovative digital services. The system consists of an industrial PC located next to each robotic paint station which has an IIoT edge installation that can control all painting processes, monitor for defects and alert operators to customized triggers. Using self-service predictive maintenance and anomaly detection, air nozzles are now cleaned only when needed to prevent contamination. Defective paint runs due to contaminated shaping air nozzles no longer happen because the new system detects such faults immediately.

Impact #1	The adoption of the Cumulocity IoT Platform has revolutionized Dürr's operations. The system has enabled the company to monitor and control all painting processes, thereby reducing defects and improving efficiency. The system also alerts operators to customized triggers, allowing for immediate action to be taken when necessary. The self-service predictive maintenance and anomaly detection capabilities have resulted in air nozzles being cleaned only when needed, preventing contamination and reducing waste. The system also detects paint dropouts, which occur when air bubbles get into the painting system, and sends instant alerts to Dürr's customers. This has not only improved the quality of the painting process but also enhanced customer satisfaction.

Impact #1

The adoption of the Cumulocity IoT Platform has revolutionized Dürr's operations. The system has enabled the company to monitor and control all painting processes, thereby reducing defects and improving efficiency. The system also alerts operators to customized triggers, allowing for immediate action to be taken when necessary. The self-service predictive maintenance and anomaly detection capabilities have resulted in air nozzles being cleaned only when needed, preventing contamination and reducing waste. The system also detects paint dropouts, which occur when air bubbles get into the painting system, and sends instant alerts to Dürr's customers. This has not only improved the quality of the painting process but also enhanced customer satisfaction.

Benefit #1	Implemented real-time monitoring for 64 robots
Benefit #2	Accelerated customer growth and planned robot purchases
Benefit #3	Generated new revenue streams from innovative digital services

Benefit #1

Implemented real-time monitoring for 64 robots

Benefit #2

Accelerated customer growth and planned robot purchases

Benefit #3

Generated new revenue streams from innovative digital services

Download PDF Version

Overview

IIoT Analytics Revolutionizing the Automotive Painting Industry: A Case Study on Dürr

Operational Impact

Quantitative Benefit