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Exhaust gas turbocharger production for Industry 4.0: Bosch Mahle Turbo Systems relies on iTAC.MES.Suite

Central MES instance rolled out for multiple plants and implemented by using a multi-tenancy architecture

Montabaur, August 4, 2015 – Bosch Mahle Turbo Systems GmbH & Co. KG follows highest Industry 4.0 standards with iTAC.MES.Suite. The Manufacturing Execution System (MES) runs alongside the entire production process and is closely intermeshed with the material logistics and the so-called business level of the company. What makes this solution special is that the central system works on the basis of a private cloud infrastructure of Bosch Mahle Turbo Systems. This enables the efficient, multi-plant use of a central MES instance.

Bosch Mahle Turbo Systems specializes in the development, production and sales of exhaust gas turbochargers. The company has now introduced iTAC’s Manufacturing Execution System since quality is the main priority throughout the entire value added chain. 

Bosch Mahle Turbo Systems aims for a zero ppm production. Therefore, traceability plays a major role. The complete traceability of all components is a complex challenge since a turbocharger consists of up to 50 individual parts. The iTAC.MES.Suite guarantees the traceability of material batches and assemblies up to the end product by recording measurement, process and error data at multiple production sites.

The challenge: Networking to meet the requirements of Industry 4.0
The primary aim is complete digitization to ensure efficient and transparent processes at the three European and the one Chinese sites. For this, a total of 400 users from the production, production planning, logistics and development units access the central MES via a private cloud infrastructure run internally by BMTS. The Chinese site has its own MES installation and communicates with the central MES instance in Stuttgart (Germany) via iTAC’s “SCT Service” (Supply Chain Traceability). The multi-tenancy architecture ensures access to a standard software platform which serves the various clients. 

“Robust data connections were essential as a result of the decision in favor of a central MES instance on a scalable cluster basis which works for multiple plants. The solution was highly available from the very outset as the entire network provided a high performance, redundant design during the implementation and start-up phases”, Ata Güleryüz, IT Manager at Bosch Mahle Turbo Systems, explains. He continues: “Another benefit, which is also a major reason behind the success of the system, is the MES’s high level of functional standardization.”
This means that all added value processes in mechanical production whose value stream extends from ERP via MES to the system controller or production process can be industrialized and digitized. 

Internationally organized: from Germany to China 
The positive experiences with iTAC.MES.Suite in Germany have led to a global roll-out; the installation in China has been completed. Since the system has a future-safe, scalable design, the next step is to roll out the existing range of functions. In addition, there are plans to expand the sectors MDC/PDC and alerts in the event of faults. Thus, Bosch Mahle Turbo Systems is prepared for the future requirements of the fourth industrial revolution.