We place great emphasis on hardware independence, both in terms of sensors and machine controls

Since 2016, we have been making our customers more successful in their IoT projects. AGC Glass Europe is the European division of AGC, a global market leader in flat glass, and produces, processes and distributes flat glass for the construction and automotive industries as well as for the solar and high-tech sectors. At the Wegberg site, AGC mainly produces front and side windows for the automotive industry.

Initial situation, challenge & solution

  • The glass panes are fitted with holders for rear-view mirrors, among other things, on several production lines. Applying the right primer in the right place is crucial for this. A number of Poka Yoke processes have already been introduced for this purpose.
  • The visualisation of the correctly produced parts and the parts that have to be reworked, including the cycle times per disc, was the desired goal.
  • We selected various Siemens PLC connectors, our OPC UA transformer and our dashboard components from our Tomorrow Labs expert modules. This enabled us to determine the cycle times per disc, per shift, per day, etc. and make them available to employees and management accordingly.
  • In addition, we were also able to visualise the Poka Yoke processes after these were also added to the machine control system and read out by our expert modules.

As a wholly owned subsidiary of Charité - Universitätsmedizin Berlin, Charité CFM Facility Management GmbH is responsible for providing all non-medical and non-nursing services. With twelve service areas, Charité CFM ensures on a daily basis that all Charité - Universitätsmedizin Berlin sites are operated efficiently - from building management, medical technology and security services to central sterilisation, logistics and catering.

Initial situation, challenge & solution

  • Over 30 external locations (mostly individual buildings spread across Berlin) have to be monitored by the maintenance team.
  • There are only collective fault reports without further details on the severity, so that for every report a technician travels through Berlin to the external site at any time to carry out a manual check.
  • Thanks to our built-in sensor technology and connection of machine control systems (including gas, water, heat pumps, BMS, humidity and temperature), the technicians now receive automated, dedicated fault messages and decide whether an ad-hoc intervention is necessary or whether the activities can be carried out as part of planned maintenance.

Our client has been assuming social responsibility for more than 110 years. With over 100 facilities and more than 3000 employees, it is on the move to help people.

Initial situation, challenge & solution

  • Legally imposed documentation obligations take up a lot of time. The digitalisation and automation of business processes is an excellent solution for relieving the burden on employees, especially at a time when there is a shortage of skilled workers in the care sector.
  • The temperature of medicine refrigerators must be checked and documented at regular intervals. This is done manually by visual inspection of the thermometer and handwritten documentation in a list.
  • Thanks to our built-in sensors and connection to our AiFO solution, no manual checking and recording is necessary.
  • The values, including the entire history, are available to the auditors at the touch of a button.

Our customer is an innovative market leader and a driving force in textile machinery manufacturing. The manufacturer offers solutions for the two most important stitch formation processes, warp knitting and knitting, as well as for the areas of technical textiles, warp preparation, weaving and digitisation.

Initial situation, challenge & solution

  • Our customer wants seamless networking between the areas of production preparation and production.
  • Instead of an MES system, they want a direct connection between SAP and the machine.
  • Using the Tomorrow Labs expert modules SAP Connector and MTConnect Connector, which we installed on a so-called edge device (industrial-grade mini PC), the bilateral exchange between SAP and the machine was made possible.
  • An order is delivered to the machine and the data previously agreed with the customer is assigned directly to the respective order and a partial selection is displayed in SAP, e.g. processing status.
  • In addition to the obvious process optimisation through direct data exchange between SAP and the machine, the data obtained is used to train predictive models (AI) to optimise usage and maintenance.

Wittenstein SE is an innovation driver in mechatronic drive technology. It develops, produces and sells customised products, systems and solutions for highly dynamic movement, the most precise positioning and intelligent networking in mechatronic drive technology.

Initial situation, challenge & solution

  • Wittenstein would like to measure and improve machine performance. To do this, you want to use the OEE (Overall Equipment Effectiveness) as a key figure.
  • Our customer has a highly heterogeneous machine landscape, i.e. data from different machine and control system manufacturers must be merged and analysed. Other platforms such as Mindsphere from Siemens do not offer these possibilities.
  • 26 machines have been connected to date via our Tomorrow Labs expert modules. Our proprietary S7 connector, MTConnect, OPC-UA connector and our OPC-UA server were used - the latter transforms the S7 protocol into OPC-UA for further use, among other things.
  • We held an initial workshop and accompanied the roll-out for 12 months.

Our client is a global family business. It is shaped by the entrepreneurial family and it thrives on the diverse talents of our members, which we value and use together. Today, 14.500 employees worldwide belong to the group of companies.Heating, cooling, ventilating: Our customer creates living spaces that meet the highest standards. This applies to comfort as well as climate protection and efficiency.

Initial situation, challenge & solution

  • Our customer mainly produces heaters at its Berlin site. Presses and welding robots from various manufacturers are used for this purpose.
  • The customer's goal is to transport and visualise the 'actual state' from the shop floor to the top floor. In addition, critical machines, such as selected welding robots (which run 24/7), should be monitored.
  • We used Siemens connectors, our Modbus connector, the OPC UA transformer and various visualisation components from our Tomorrow Labs expert kit to provide the required information directly on the shop floor, i.e. at the machines, and in a management dashboard.
  • In the event of deviations from the specifications or error messages from the machines, the relevant persons are notified immediately.

Caverion stands for 'Building Performance', for technical building equipment in all trades. To this end, we plan and construct technical building systems and take care of service and maintenance. We cover the entire life cycle of a building - whether it is an office complex, industrial plant, airport, hospital or congress centre.

Initial situation, challenge & solution

  • Caverion monitors various sprinkler systems for its customer.
  • The monitoring and testing tasks are precisely specified. A continuous visual inspection of the pressure gauges and controller positions are part of this.
  • It should be checked which technology can be used for monitoring in order to subsequently carry out a profitability analysis.
  • After selecting a suitable infrared camera, various ML and AI models (openCV and Tensorflow) were evaluated - including those we developed ourselves, which are already used to read water meters.

Kaspersky protects more than 400 million people and 240.000 businesses worldwide. Kaspersky is one of the largest privately held cyber security companies in the world. Their holding company is registered in the UK, they operate in 200 countries and territories and have 34 offices. The team consists of over 4500 highly qualified specialists.

Initial situation, challenge & solution

  • Kaspersky developed a cyber defence that enables direct monitoring of production facilities at control level. This solution was developed after the attack (Stuxnet attack) on the Iranian nuclear power plant was publicised.
  • Together with the developers of the KICS (Kaspersky Industrial CyberSecurity) solution, we carried out the commissioning at our customer AGC Glass in Germany.
  • Download Use Case:

Loyalty Prime Germany GmbH developed a customer loyalty platform as SaaS (Software-as-a-Service). The company offers a cloud platform with online membership, user access security, automated marketing campaigns, web portal, mobile application, SMS, social media, content management and analytics services. Loyalty Prime served customers worldwide.

Initial situation, challenge & solution

  • Our customer had outsourced the entire development to India. As a result, their cloud solution did not meet the usual market standards in terms of performance and security, which meant that potential customers such as the Metro Group could not be convinced.
  • The customer was looking for a service provider who could design and develop a cloud-native solution.
  • With the help of our Tomorrow Labs Libraries, we developed a solution within 12 months that was so variable and performant that customers such as Heineken, Allianz, Toyota USA and ultimately the Metro Group were convinced of the technical and user benefits of the software.
  • We supported the solution for a further 12 months. During this period, we built up internal resources for the customer in Germany and handed them over to the customer in full.
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