BMG Intelligent Production Suite (IPSuite)

BMGs Intelligent Production Suite (IPSuite) brings intelligence to manufacturing through data-driven applications designed to maximize productivity and process stability. Today, IPSuite already enables the first production stations to optimize themselves autonomously, increasing efficiency, robustness, adaptability, and process stability. The goal: production systems that are efficient, robust, adaptable, and increasingly autonomous.

Transparency & Analytics

Operational Insights
Process & Analytics
Sustainability

Operational Continuity

Preventive Maintenance
Predictive Maintenance
Corrective Maintenance

Control & Optimization

Autonomous Processes
Autonomous Line & Value Stream

Transparency & Analytics

Operational Insights

Awareness & highlighting (Andon)

Benefits

Easy data collection to support setup of plant data platform
Immediate reduction of machine downtimes as well as long-term competence build up

Awareness & highlighting (Andon)

Customized and live visualization
Middleware between machine and data platform
Support for 2D and 3D visualization
Drag-and-drop visualization

Benefits

Easy data collection to support setup of plant data platform
Immediate reduction of machine downtimes as well as long-term competence build up

Operational Insights

Asset health

Benefits

Easy configurable notifications and alerts
Implementation of predictive maintenance and response to malfunctions
All relevant data at a glance

Asset health

Comprehensive view of machine status
Configuration of notifications and alarms as well as creation of pre-defined graphs and reports
Web-based dashboards accessible via standard browsers
Mobile app
Widget-based dashboard layout for flexible KPI representation

Benefits

Easy configurable notifications and alerts
Implementation of predictive maintenance and response to malfunctions
All relevant data at a glance

Operational Insights

Cycle time & dynamic bottlenecks

Benefits

Fast setup, especially in Control Plus-based machines
Detailed listing of all times contributing to the cycle time

Cycle time & dynamic bottlenecks

Recording of a machine's cycle time information
Fast identification of cycle time losses
Quick identification of root causes of cycle time deviations
Cycle Time Assist can be installed per machine or connect multiple machines for analysis at the edge level

Benefits

Fast setup, especially in Control Plus-based machines
Detailed listing of all times contributing to the cycle time

Process & Analytics

Process metrics

Benefits

Reduced commissioning time
Avoiding additional material cost by preventing e.g. tool damage
85% of time effort saved during failure analysis

Process metrics

Visualization of process parameters
Basis for deciding when and with which technical measures to intervene in production processes
Numerous interfaces which can easily be expanded into a process control system
User can view Process Monitoring using any browser connected to the server

Benefits

Reduced commissioning time
Avoiding additional material cost by preventing e.g. tool damage
85% of time effort saved during failure analysis

Process & Analytics

Production parameters

Benefits

High quality assurance
Product-recall reduction by 95% due to incorrect parametrization

Production parameters

Provides a global overview of all connected stations, machines and lines producing the same part types
Compares parameters and displays failure alerts in case of discrepancies
Quick overview of process parameters worldwide

Benefits

High quality assurance
Product-recall reduction by 95% due to incorrect parametrization

Sustainability

Energy consumption

Benefits

Native integration with production (not standalone)
Correlation: energy ↔ process ↔ machine
High-granularity data
Enables cost reduction & sustainability

Energy consumption

Collects energy data from machines via OPC-UA
Processes and stores time-series data
Analytics to detect inefficiencies and optimize consumption
Connectivity: OPC-UA
Scalable: machine → line → plant
Monitoring + historical analysis

Benefits

Native integration with production (not standalone)
Correlation: energy ↔ process ↔ machine
High-granularity data
Enables cost reduction & sustainability

Operational Continuity

Preventive Maintenance

Closed-loop ticketing

Benefits

Reduced downtimes
Knowledge-based repair

Closed-loop ticketing

Event-triggered alerting and information sharing to configurable target groups
Freely configurable with respect to information channels, routing and user groups
Event context and reaction history provided
Available within IPSuite Portal and Mobile App for iOS & Android

Benefits

Reduced downtimes
Knowledge-based repair

Predictive Maintenance

Predictive analytics

Benefits

Fast, easy to deploy and scalable to monitor several machines at once
Can be deployed on-premise or in the cloud
Minimal training effort for the ML model, as it can be generalized for many use cases

Predictive analytics

Learns machine degradation behavior and predicts the Health Index (HI) of the machine
By extrapolating HI and combining domain expertise from process experts, the remaining useful life is predicted
Data can be cyclic data, continuous event data or process data

Benefits

Fast, easy to deploy and scalable to monitor several machines at once
Can be deployed on-premise or in the cloud
Minimal training effort for the ML model, as it can be generalized for many use cases

Corrective Maintenance

Anomaly detection

Benefits

Increased Quality Assurance
Engineers can quickly identify root causes and resolve issues

Anomaly detection

Enhances manufacturing quality control by identifying deviations in data
Enables early detection of anomalies, prevents defects, and reduces costs associated with rework or failures
Flexible architecture that supports integration into various manufacturing processes

Benefits

Increased Quality Assurance
Engineers can quickly identify root causes and resolve issues

Corrective Maintenance

Event-related video footage

Benefits

Faster error analysis by automatic and quick selection based on failure events
Reduction of ramp-up time for new machines and processes

Event-related video footage

Automatically records and links video footage to machine events
Makes production incidents instantly visible and easy to analyze
Up to 4 cameras per machine
Process and failure analysis based on data and machine status

Benefits

Faster error analysis by automatic and quick selection based on failure events
Reduction of ramp-up time for new machines and processes

Corrective Maintenance

Virtual root cause localization

Benefits

Very fast application
Import of the machine's 3D model (e.g., from a mechanical tool) and linking of error numbers and 3D components
4 hours setup time for a typical project

Virtual root cause localization

Displays machine events, such as errors, in a 3D model of the machine
Highlights faulty machine components
Enables users to find the correct location for troubleshooting
Freely configurable error information
Free assignment to parts of the 3D model
Available as a standalone solution for installation in a Windows or ctrlX OS environment

Benefits

Very fast application
Import of the machine's 3D model (e.g., from a mechanical tool) and linking of error numbers and 3D components
4 hours setup time for a typical project

Control & Optimization

Autonomous Processes

Process model generation

Benefits

Time efficiency in product or process development by > 30%
Usage of analytics pipelines without deeper data analytics knowledge

Process model generation

Fully integrated toolchain for product development and process optimization
Standardized development workflow
Semantically rich data model and analytics pipelines
All required software components are provided by BMG as a service

Benefits

Time efficiency in product or process development by > 30%
Usage of analytics pipelines without deeper data analytics knowledge

Autonomous Processes

Process parameter optimization

Benefits

Scrap reduction by keeping machine (e.g. against drifts) in optimum parameter settings (proven use case: 250k€ savings per line per year)
Data visualization through generation of process models to analyze the process
Support for process experts in multidimensional space (>3D)

Process parameter optimization

AI and data supported optimization & development of manufacturing processes
Assistance in multidimensional space (many different parameters & quality criteria) by visualization of models and optimal areas for production
Web applications with user guidance
Machine interface via different communication protocol (e.g. OPC – UA)
Flexible interface to integrate customer algorithms (e.g. Python) for control loops
Bayesian Optimization (ML) & Gaussian Process Models (ML)

Benefits

Scrap reduction by keeping machine (e.g. against drifts) in optimum parameter settings (proven use case: 250k€ savings per line per year)
Data visualization through generation of process models to analyze the process
Support for process experts in multidimensional space (>3D)

Autonomous Processes

Custom algorithm execution

Benefits

Creation of flexible algorithms in Matlab or Python – doable by user
Built-in bi-directional connectivity enables usage on different levels
Option available for application & monitoring of AI models

Custom algorithm execution

Freely programmable data processing platform
For applications in surveillance, analysis and adaptive control of assembly & production processes
Adaptive parameter control to ensure process stability and scrap reduction
Surveils tolerance violations of process variables and creates events (e.g. which can be sent out as tickets to operators via Maintenance Ticket System (MTS))
Detects long-term drifts of process variables

Benefits

Creation of flexible algorithms in Matlab or Python – doable by user
Built-in bi-directional connectivity enables usage on different levels
Option available for application & monitoring of AI models

Autonomous Processes

Statistical process control

Benefits

End-to-end solution combining monitoring, alerts, and Maintenance Ticket System workflows
Highly configurable and easily extendable via Node-RED
Fast implementation and seamless Bosch ecosystem integration

Statistical process control

Live monitoring and analysis of machine and process data
Automated rule evaluation, notifications, and ticket creation via Maintenance Ticket System
Historical data analysis up to 1.5 years
Configurable rules, notifications, and role-based access management

Benefits

End-to-end solution combining monitoring, alerts, and Maintenance Ticket System workflows
Highly configurable and easily extendable via Node-RED
Fast implementation and seamless Bosch ecosystem integration

Autonomous Line & Value Stream

Line and shopfloor control

Benefits

Fast, easy to deploy and scalable to monitor several machines at once
Can be deployed on-premise or in the cloud
Minimal training effort for the ML model, as it can be generalized for many use cases

Line and shopfloor control

Central line control with assignment of production orders
Material and transport logic
Live data acquisition
Data can be cyclic data, continuous event data or process data
Customer data must be available in SL3 or SL4

Benefits

Fast, easy to deploy and scalable to monitor several machines at once
Can be deployed on-premise or in the cloud
Minimal training effort for the ML model, as it can be generalized for many use cases

Foundation

Universal Connectivity

Universal Machine Connector (UMC)

Benefits

Faster machine integration
Enables a standardized interface layer across the shopfloor
Continuous acquisition of machine and process data

Universal Machine Connector (UMC)

Connects machines independent of manufacturer, age or control type
Transforms machine data into a consistent and structured format
Bidirectional data transfer
Multiple parallel connections via additional licenses

Benefits

Faster machine integration
Enables a standardized interface layer across the shopfloor
Continuous acquisition of machine and process data

Structured Experience Sharing

Experience Share System

Benefits

Reduced downtime
Reuse of experiences across lines and plants
Preserve expert knowledge

Experience Share System

Capture production experiences and best practices
Structured knowledge base for lines, stations and machines
Link solutions directly to machine errors and events
Mobile and desktop access for operators and experts

Benefits

Reduced downtime
Reuse of experiences across lines and plants
Preserve expert knowledge

UMC App by Bosch for machine integration via ctrlX OS – digital manufacturing solution

UMC for seamless machine connectivity

Simplify your machine integration with the Universal Machine Connectivity (UMC) App – now available in the ctrlX OS Store.

Discover the UMC App

Benefits at a glance

Productivity

Increased productivity thanks to optimized machine and system availability

Efficiency

Increased efficiency thanks to optimized processes and high process reliability

Costs

Reduced costs thanks to optimized system availability, optimized processes and reduced maintenance costs

Hannover Messe 2024 Bosch Manufacturing Solutions

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BMG Intelligent Production Suite (IPSuite)

Transparency & Analytics

Operational Continuity

Control & Optimization

Transparency & Analytics

Awareness & highlighting (Andon)

Asset health

Cycle time & dynamic bottlenecks

Process metrics

Production parameters

Energy consumption

Operational Continuity

Closed-loop ticketing

Predictive analytics

Anomaly detection

Event-related video footage

Virtual root cause localization

Control & Optimization

Process model generation

Process parameter optimization

Custom algorithm execution

Statistical process control

Line and shopfloor control

Foundation

Universal Machine Connector (UMC)

Experience Share System

UMC for seamless machine connectivity

Benefits at a glance

Productivity

Efficiency

Costs

Got questions? We are here for you!

Further information

Intelligent Production Equipment & Automation

News & Events

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