Top Condition Monitoring Companies in Germany

Use case

Thickness measurement of metal products

steel, metal, aluminium, aluminum, copper

Our radar sensor solution determines the thickness and the thickness profile of steel plates, steel strips or steel slabs (up to 1600 °C hot) with an accuracy of up to ±10 µm on the roller conveyor. Thanks to robust radar technology, sophisticated signal processing and intelligent radar algorithms, OndoSense radar sensors achieve this high level of precision in thickness measurement even under the difficult production conditions of the steel industry with smoke, steam, dirt, vibrations, fire and extreme temperatures.

Use case

Width measurement of metal products

metal, steel, copper, aluminium, aluminum

The OndoSense radar sensor solution determines the width of steel plates, steel strips or steel slabs (up to 1600 °C hot) with an accuracy of up to ±300 µm. Thanks to robust radar technology, sophisticated signal processing and smart radar algorithms, our radar sensors offer this high precision in width measurement even in the extreme production environments of the metal and steel industry with steam, dirt, smoke, fire, vibrations and extreme temperatures.

Use case

Molten metal level measurement

metal, steel, copper, aluminium, aluminum

With the OndoSense radar sensors, the fill level of liquid steel or aluminum can be measured contact-free with sub-millimeter accuracy, even at metal temperatures of up to 1600 degrees Celsius. Dust, steam, smoke, vibrations and strong heat radiation have no influence on the high precision and reliability of the radar-based molten metal level monitoring. Active cooling of the level radar is usually not necessary.

Use case

Continuous monitoring

Manufacturing

The challenge Blickle has always prided itself on the superior quality of its wheels and castors. To further enhance this quality with modern technology, the company decided to migrate its production processes to Industry 4.0 standards. This planned transition should have minimal impact on the three-shift production operation, while maintaining flexibility and openness for future digitalization initiatives. The solution Blickle IT developed a concept to enable a sustainable and gradual transformation. At the heart of the strategy is edbic, which enables condition monitoring. Acting as a central data hub, edbic seamlessly extracts data from the machines, transfers it to the ERP system and provides full production transparency. The result With the implementation of edbic, machine data no longer reaches IT incomplete or delayed. Immediate data analysis enables rapid problem resolution. Automatic punching presses are monitored to determine output results, missing parts, quantities and more. By eliminating most of the Excel lists previously used, edbic has significantly streamlined operations. In polyurethane production, edbic identifies and corrects problems, contributing to Blickle's high quality castors and wheels. In addition, edbic is now being used beyond production, facilitating connections to payment providers in the web shop and establishing a communication link with SAP. Outlook for the future Blickle plans to further refine the system by using machine data comparison for predictive maintenance. In addition, the company is considering implementing the compacer IoT gateway to take communication between machines and the ERP system to a new level of automation.

Use case

IoT gateway and Industry 4.0 application

Industry 4.0, Manufacturing

The challenge: BURKHARDT+WEBER is renowned for its expertise in large machining centres. Headquartered in Reutlingen, Germany, the company has a global presence and supplies its products to customers around the world who place a premium on quality. For 130 years, BURKHARDT+WEBER has focused on developing state-of-the-art production solutions for the demanding machining of steel, cast iron and titanium components. The development of these machining centres is the collaborative work of interdisciplinary teams, and all essential components, as well as in-house developments, are manufactured within the company. The compacer IoT solution, built on the edbic platform, is planned for future integration into BURKHARDT+WEBER machining centres. The installation of the compacer IoT gateway enables data collection from the machine's control system. In the long term, BURKHARDT+WEBER machines will offer a wide range of data that can be examined in real time to provide a detailed overview of the machine's condition and efficiency on a dashboard. The solution: An IoT hub will process the collected data, enabling a variety of assessments and ensuring that the operator is kept informed at all times. With machines connected to the compactor solution, condition monitoring is possible, paving the way for the implementation of predictive maintenance. With this approach, BURKHARDT+WEBER enables its customers to successfully implement upcoming digital transformation projects within their production processes.

Use case

Continuous monitoring

Airport, Logistics

The challenge: A leading provider of ground services and cargo handling wanted to offer comprehensive solutions to the aviation industry. To drive innovation in key areas such as service, quality and reliability, the company wanted to improve visibility and communication through integration and networking across departments. Monitoring irregularities in process flows was critical to optimizing ground handling services. Working with multiple service providers and their disparate IT systems, which varied between airports and internal departments, was a challenge, while maintaining uninterrupted operations throughout the project. The solution: This multi-stage project used edpem, a process event monitoring tool, as the primary solution for monitoring ground services. To ensure fast aircraft turnaround times, the critical path in the process flow needed to be measured and monitored, especially when processes were transferred between suppliers. edpem recorded multiple events, including parking, disembarking completion, cleaning, catering, fuelling, crew boarding and loading completion. Service Level Agreements (SLAs) were tracked and monitored, and causes of delays identified and improved. Ground handling services were optimized by assessing service duration and process flow irregularities. In addition to monitoring traditional EDI processes, visualized reports improved reporting efficiency and facilitated faster decision-making. Key results included reduced turnaround times and fewer disruptions to flight operations. Our client: A major European airport provides ground services to approximately 265 million passengers annually and manages 4.6 million tonnes of global air cargo. Several warehouses are IATA CEIV certified for pharmaceutical logistics. In 2019, its 64,000 employees operated at 300 airports in 47 countries on six continents.

Use case

Continuous monitoring

Logistics

The challenge: The pharmaceutical company works closely with logistics service providers. Due to the volatile nature of the sector's order book, it was difficult to accurately predict capacity utilization, leading to recurring problems with service providers during collection. Service providers need timely information on freight volumes, collection details and the appropriate mode of transport. A key challenge was the sharing of real-time transport data. Another key concern was tracking and tracing, which proved difficult due to incomplete integration of certain areas of the warehouse management system. In addition, real-time monitoring of internal and external departments and service providers was required to optimize logistics processes. The solution: edpem was implemented as an end-to-end monitoring solution to improve logistics processes. The monitoring covered the entire delivery process, from SAP order documents and invoices to final delivery. Connection and monitoring of the warehouse management system was also part of the scope. Comprehensive tracking of goods throughout the supply chain enabled quick retrieval of information without involving other departments, saving valuable time and resources. Optimal vehicle selection for parcel collection and product tracking by batch were achieved. Internal IT system security was ensured, as external partners could only access edpem without needing permissions for internal applications. Parcel scanning enabled customer order tracking and tracing, early problem identification and real-time notification of process owners. edpem tracked the entire shipping process from packaging to customer delivery. The automation of electronic data interchange (EDI) provided new opportunities for superior service and quality for customers and logistics providers. Our customer: A pharmaceutical company based in Germany provides "Made in Germany" products to patients worldwide, with almost all products manufactured at its headquarters in Baden-Baden and distributed through an extensive network. Its main focus is on the research and production of medicines based on natural ingredients. The company has achieved global growth and operates in 50 countries.