Reduce unplanned downtime in a highly automated
production environment at the Siemens factory in Cham (Bavaria).
Improve productivity, asset transparency, and maintenance
efficiency across critical motor‑driven components.
Transition from reactive or time‑based maintenance to predictive
maintenance using real‑time insights.
Achieve a solution that works in a brownfield setup,
avoiding major overhauls and integrating into existing systems.
Increase equipment reliability, maintaining consistent
output and preventing negative downstream effects such as customer
dissatisfaction and productivity losses.
Build a scalable approach that can be rolled out to other
production lines and locations.
Implementation of a combined hardware and software
digitalization approach that bridges the shop floor and IT levels.
Smart Siemens hardware installed on
existing equipment:
SIRIUS 3RC7 ILM
(Intelligent Link Modules)
SIRIUS 3RW5 Soft starters
SIMATIC ET 200SP
e-Starter
Full portfolio of motor monitoring and control devices
capturing data such as torque, current, voltage, temperature, energy,
cycles, runtime, etc.
Hardware connected seamlessly within the TIA Portal / Step 7
environment for fast integration.
Pre‑processing logic added to the PLC for secure and structured
data transfer.
Detects anomalies, thresholds, patterns and produces explanations,
root‑cause suggestions, and remedy recommendations.
Provides maintenance technicians with remote access, case
views, evidence, and a Co‑Pilot chat for guided troubleshooting.
End‑to‑end data pipeline using industrial communication
protocols:
Shop floor: PROFINET, Modbus TCP, Ethernet/IP
Cloud transfer: MQTT
Siemens Services supported the setup using standardized
blueprints, KPI definition workshops, asset onboarding support, and
implementation guidance.
Significant reduction of unplanned downtime by predicting failures before they occur.
Clear visibility into the health and condition of more than
90 assets in the pilot line.
Early detection prevented several production stoppages—each
potentially costing several days of lost output.
Improved maintenance efficiency:
Technicians receive actionable insights instead of raw data.
Faster root‑cause finding, less firefighting.
Increased production reliability, customer satisfaction,
and internal productivity.
Cost savings through proactive
maintenance (avoiding 3–5× higher costs linked to unplanned breakdowns).
Solution implemented with minimal disruption to existing
operations (brownfield retrofit).
Scalable approach now being rolled out to other lines in Cham,
Amberg and additional Siemens factories.
Siemens Factory Cham, located in Eastern
Bavaria, is part of the Siemens Electrical Products factory network. It
specializes in producing contactors, motor starter protectors, overload relays,
and other low voltage portfolio components. Approximately 470 employees work
across its two production halls, which span about 16,000 m².
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